Personalized fit and functional designed medical prostheses and surgical instruments and methods for making

ABSTRACT

The present invention provides methods, devices, systems, and instruments related to medical implants and surgical instruments produced to precisely fit individual subjects. In particular, the present invention utilizes a combination of medical imaging, quantitative image analysis, CAD, CAM, and additive manufacturing processes to personalized biocompatible devices.

This application claims priority to U.S. Provisional Application No.61/169,572 file Apr. 15, 2009, which is incorporated by reference in itsentirety.

FIELD OF THE INVENTION

The present invention provides methods, devices, systems, andinstruments related to medical implants and surgical instrumentsproduced for personalized fit and/or personalized function of individualusers. In particular, embodiments of the present invention utilize acombination of medical imaging; quantitative image analysis; computeraided design, manufacturing, and engineering; telemedicine; virtualdesign collaboration, virtual design simulation and validation;informatics; mass-customization production; and additive manufacturingprocesses to personalize biocompatible devices for fit and/or function.In some embodiments, a production system is statistically controlledenabling the repeatability of the system to be probabilisticallyforecasted and the accuracy of features produced for medical implantsand surgical instruments statistically controlled to enablemass-customization and increase speed of the overall system withoutjeopardizing product quality.

BACKGROUND OF THE INVENTION

Medical implants have dramatically improved the quality of life for manypersons. Orthopedic devices such as total artificial hips, totalartificial knees, fracture fixation plates, various fixtures, pins,wires, nails, intramedullary rods, and many others have enabled subjectsto return to a high level of functioning, while restoring quality oflife following debilitating diseases such as osteoarthritis,osteosarcoma, and physical trauma. Current orthopedic devices used forthese and other skeletal corrections and repairs are produced in avariety of sizes to fit a range of subjects and needs. Typically themedical professional will attempt to choose the appropriate size andshape of the prosthetic device prior to surgery or intraoperatively.However, this protocol is not always successful. Often the surgeon mustchoose between one device that is too large, a second that is too small,and a third that is closer in size, but not quite the correct shape.Each patient has a unique need in an orthopedic device due to theinfinite variation of subject anatomy combined with the infinitevariation of disease and/or trauma. Although surgeons can oftenimprovise the fit through selective removal of the subject's bone,removing otherwise healthy or undamaged tissue is not desirable, and thefit will in most cases still be less than optimal. In some cases it maybe possible for the surgeon to modify the device to make a better fit,but it is not generally feasible to machine, bend, grind, drill orotherwise modify the structure of the materials used for orthopedicdevices within the constraints of the operating theater. Additionally,the variety of sizes of current orthopedic devices are to accommodatedifferent ranges of anatomical features and do not account fordifferences in patient activity level.

Newer methods using finite element analysis (FEA) for use in rapidprototyping have been discussed, see for example, B. V. Mehta, Annals ofBiomedical Engineering, Blackwell Science, Inc., Vol. 23, S.1, 1995, pp.9. While such methods discuss three-dimensional (3D) imaging of theimplant site and design of an implantable device, their uses are limitedto rapid prototyping and do not allow for the production of an actualprosthesis or usable article.

Johnson et al., U.S. Pat. No. 7,105,026, disclose a modular kneeprosthesis. This prosthesis attempts to solve the problem of soft tissuebalancing, which requires a surgical compromise to achieve a balancebetween flexion and extension gaps. Johnson et al. disclose a modularknee system having various distal posterior femoral components that areinterchangeable so that the surgeon can choose the most correctcompromise. Similarly, Sanford et al., U.S. Pat. No. 6,916,324, disclosea provisional orthopedic prosthesis for partially resected bone.Briefly, disclosed is a provisional orthopedic prosthesis having a firstprovisional component and a second optional component. The provisionalcomponent is used to assess the fit of a permanent prosthesis and ismounted on a partially prepared bone so as to allow a permanentprosthesis to be more accurately fitted. In both cases the finalprostheses require an initial fitting or optimization of a genericprosthesis to achieve the fit of the permanent prosthesis.

Similarly, medical instruments are produced and manufactured in a seriesof standard sizes so as to best approximate the need of the users. Insuch cases the length, size and grip of an instrument are generally notavailable in custom sizes, personalized designs or custom alloycombinations. In such cases, the physician or end-user is limited to thebest fit, weight or alloy available. In these cases, it would be helpfulfor the practitioner if there were medical instruments available thatwere a personalized fit for the size and grip of the user. Balance andweight of instruments may be controlled through internal features suchas hollow, honeycomb, ribbed or a combination of these features. Suchinternal features have been difficult or impossible to produce beforethe advent of additive manufacturing technology which is incorporatedinto the invention.

SUMMARY OF THE INVENTION

Generally, the present invention provides systems, methods, techniques,materials and devices and uses thereof for personalized fit and/orpersonalized function biocompatible implants, prosthetics andinterventional instruments for use in medical and veterinaryapplications. The devices produced according to the invention arecreated by referencing a patient profile (case) or, in the case ofpersonalized surgical instruments, a surgeon profile. The devices arethen produced using additive manufacturing techniques based on acomputer generated model such that every prosthesis or interventionaldevice is personalized for the fit and/or function of the user havingthe appropriate material composition and virtual validation offunctional design for each use.

In some embodiments, design selection is based on the patient or surgeonprofile in combination with historic patient or surgeon data to provideenhanced design. For example, in some embodiments, a database isinterrogated to identify prior cases or profiles and their outcomes toassist in the optimization of a design for a current patient or surgeoncase. Thus, the systems and methods provide for learning from historicalcases and successes and challenges of variables dealt with in the past.In some embodiments, a newly defined case-based reasoning (CBR) expertsystem architecture will provide the engine for this invention's designoptimization approach. This CBR engine will quickly enable personalizedmedical device designers to learn from past cases, while focusing on newvariables that have not been dealt with in the past. The cycle will berepeated over hundreds of thousands of cases and the intelligenceincorporated into the CBR expert system will enable medical devicedesigners to become very accurate with features they design intoimplants and surgical instrumentation. Long-term successes or challengesof previous personalized medical device designs will be captured througha registry system to track patients' and surgeons' use of implants andsurgical instrumentation. These data too will be available through theCBR expert system.

A unique feature of some embodiments of the invention is the use ofpreliminary designs based on patient profiles or surgeon profiles thatpermit feedback from the surgeon prior to production of the device. Forexample, in some embodiments, a design that incorporates patient orsurgeon profile information and, optionally, historical caseinformation, is presented to the surgeon for preliminary evaluation. Thedesign is presented to the surgeon in a manner that permits the surgeonto evaluate the position and function of the device using 3D CAD models,as well as permitting the surgeon to observe and test performanceparameters using computer simulation. The surgeon can select orrecommend design changes that incorporate patient- or surgeon-specificneeds based on the wisdom and experience of the surgeon and the newdesign can be submitted and tested, and if desired, re-evaluated priorto selecting a final design prior to release to production. In someembodiments, collaboration between the surgeon and design/productiongroup occurs virtually, over an electronic communication network. Insome embodiments, prior to device production, the surgeon engages avirtual simulation session of the surgery such that the personalizeddevice is implanted into a virtual model of the patient.

Another unique feature of some embodiments of the invention is the useof computer assisted surgery (CAS) using robotics to assist theorthopedic surgeon in resecting the bone, eliminating sharp edgestypically associated with traditional surgical approaches and producinga geometrically precise pocket or mounting surface for the device frompatient specific data. For example, in some embodiments, after thesurgeon has made the incision, clamped back the surrounding soft tissueand exposed the bone in preparation for the resection event, a roboticsurgical system is used to create a contoured resection based on thepreliminary and virtual design of the device. Upon the initial resectionof the bone, the robot transverses to a resting position out of the wayof the surgeon. The surgeon removes the resected bone and starts thenext robot sequence for removing sharp edges cases from the resectionevent. Once this operation is completed by the robot surgical system,the precise pocket or mounting surface for the device is created. Oncethe robot completes its work, it moves to a resting position out of theway of the surgeon. The surgeon, irrigates the area, vacuums the area,implants the device and closes. Prior to surgery, the robot isprogrammed based on the authorized and final implant design employingpatient-specific information and incorporating surgeon feedback from thepreliminary design phase. In some embodiments, the surgeon controls whenthe robot starts and stops its work. This coordination between thesurgeon and robot is enhanced by the surgeon's prior virtual surgicalsimulation session of the surgical procedure. In some embodiments, therobot is used principally to improve the resection process to provideprecise geometries optimized for the personalized device and to avoidunnecessary removal of natural bone. In some embodiments, the surgeonpreselects resection conditions, based on individual judgment, to meetthe performance and lifestyle needs of the individual patient. Forexample, a young athlete may have different natural bone retention needsor device positioning or performance needs than an elderly person havinga largely sedentary lifestyle. In some embodiments, the robotic systemfurther is used to radius any sharp edges due to the resection processwhich can create problems during the rehabilitation phase for thepatient. This invention is a revolutionary system of systems approach toimproving the precision of the resection event and to improve the fitbetween the bone and implant, eliminating the need for bone cement andreducing recovery time for the patient to regain his or her previouslevel of functioning. From an administration perspective, the system ofsystems approach enables the medical institution to conduct moresurgeries per day, per surgeon, while minimizing risks associated withfailed surgeries requiring revision surgeries.

In some embodiments, the present invention provides a method ofpersonalizing a biocompatible device, comprising the steps of: (a)obtaining a profile of the subject, including, for example, medicalhistory, imaging and/or genomic data, (b) producing a virtual 3D designmodel, wherein the virtual 3D design model is configured to parametersfrom the subject profile, and (c) production of a biocompatible device,wherein the biocompatible device is configured to the physicalspecifications of the virtual 3D design model. In some embodiments, thepresent invention provides a step prior to step (a) of evaluating thesubject by an orthopedic surgeon. In some embodiments, the presentinvention provides a step prior to step (a) of referring the subject toan orthopedic surgeon. In some embodiments, the present inventionprovides a step prior to step (a) of educating clinicians about thepersonalized biocompatible devices of the present invention. In someembodiments, the input imaging data is received from CT, MRI, PET,digital X-ray, ultrasound or other scanning of the subject. In someembodiments, the present invention provides a step following step (a)but prior to step (b) of transferring subject information to adesign/design validation/production system. In some embodiments, thepresent invention provides generating a subject profile and case number.In some embodiments, producing a virtual 3D design model comprisescalibrating, analyzing and producing a 3D CAD solid model from inputimaging data. In some embodiments, producing a virtual 3D design modelcomprises one or more of CAD, computer aided manufacturing (CAM), FEA ofbiological tissue of the subject, FEA of materials, joint articulationanalysis, solid modeling or 3D visualization instruments and methods. Insome embodiments, producing a virtual 3D design model comprises one ormore of the steps of: i) creating a 3D surface model of the bone andsurrounding soft tissue/cartilage of the subject, wherein the 3D surfacemodel is configured to the parameters from imaging of the subject, ii)creating a preliminary personalized fit and/or personalized functionmodel, wherein the preliminary model is configured to the subjectprofile, and iii) designing a personalized biocompatible device, whereinthe biocompatible device is configured to accurately fit the 3D surfacemodel of the bone of the subject, subject profile variables, and qualityof the preserved bone. In some embodiments, the present inventionprovides a step following step (b) but prior to step (c) of evaluating avirtual 3D design model. In some embodiments, evaluating the virtual 3Ddesign model comprises performing a device simulation to analyze avirtual 3D design model. In some embodiments, the device simulationcomprises a joint articulation simulation to analyze the motion of ajoint by simulating the relevant daily activities of a patient orsurgeon. In some embodiments, evaluating a virtual 3D design modelcomprises performing FEA, wherein FEA assesses function such asforces/stresses involved at the joint articulation and joint/boneinterface of the personalized biocompatible device based on a subjectprofile. In some embodiments, evaluating a virtual 3D design modelcomprises performing a joint articulation simulation to validate thefunctioning of the device through simulated motion of the patientanatomy. In some embodiments, evaluating the virtual 3D design modelcomprises performing surgical simulation. In some embodiments,evaluating a virtual 3D design model comprises using a single hybridmodel which includes combined and universal data sets for FEA, jointarticulating simulation and surgical simulation. In some embodiments,the present invention provides a step following step (b) but prior tostep (c) of off-line programming a computer assisted surgery (CAS)system. In some embodiments, the present invention provides a stepfollowing step (b) but prior to step (c) further comprising verifying aCAS program using a virtual 3D model of the subject and a surgicalrobot. In some embodiments, the present invention provides a stepfollowing step (b) but prior to step (c) of collaboration between thesurgical team and the design/manufacturing team to finalize the designof the personalized biocompatible device. In some embodiments, remotecollaboration between the surgical team and the design/production teamcomprises reviewing and/or modifying the virtual 3D design model by thesurgical team. In some embodiments, remote collaboration between thesurgical team and the design/production team comprises reviewing and/ormodifying said virtual 3D design model by the design/production team. Insome embodiments, modifications are evaluated by FEA, joint articulationsimulation, surgical simulation, and/or CAS validation. In someembodiments, the present invention provides a step following step (b)but prior to step (c) of authorizing design of the personalizedbiocompatible device by the surgical team. In some embodiments, thepresent invention provides a step following step (b) but prior to step(c) of releasing the design to production. In some embodiments, thepresent invention provides a step comprised of producing a 3D physicalmodel of the biocompatible device and a 3D physical model of the bone ofthe subject. In some embodiments, the 3D physical model of thebiocompatible device and a 3D physical model of the bone of the subjectare used for surgeon and/or subject education. In some embodiments,production of the biocompatible device comprises additive manufacturingtechnology. In some embodiments, production of the biocompatible devicecomprises automated multi-axis computer numerical control (CNC) grindingand polishing of the biocompatible device. In some embodiments, thepresent invention provides a step following the production of thebiocompatible device with one that comprises verifying surface finishand dimensional quality of the biocompatible device. In someembodiments, production of the biocompatible device comprises additionof biomaterials and/or stem cells to fight bacteria and the like and/orfor tissue regeneration to the biocompatible device. In someembodiments, production of the biocompatible device comprises drugeluting functionality. In some embodiments, production of thebiocompatible device comprises sterilization of the biocompatibledevice. In some embodiments, the present invention provides a stepfollowing step (c) of shipping the biocompatible device to the surgicalteam. In some embodiments, the present invention provides a stepfollowing step (c) of implanting the personalized biocompatible deviceinto the subject. In some embodiments, implanting is performed in wholeor in part by a surgeon. In some embodiments, implanting is performed orassisted by a CAS system. In some embodiments, a CAS continuously alignsto the subject's anatomical features to self-orient the positioning axesof the CAS and robot arm. In some embodiments, the present inventionprovides a step following step (c) of verifying the fit of thebiocompatible device. In some embodiments, verifying comprises magneticresonance imaging (MRI), nuclear magnetic resonance (NMR), digitalX-ray, computed tomography (CT), ultrasound, LASER interferometry orpositron emission tomography (PET) scanning of the subject. In someembodiments, the present invention provides a step following verifyingdata of adding the verification data to a subject profile. In someembodiments, the present invention provides a step following step (c) ofrehabilitating the subject. In some embodiments, the present inventionprovides a step following step (c) comparing actual implantation resultsto results from device simulations. In some embodiments, the presentinvention provides a method of personalizing a biocompatible device,wherein calibrating, analyzing and producing a 3D CAD solid model frominput imaging data is performed through CAD, CAM, FEA of biologicaltissue of the subject, FEA of materials, joint articulation simulation,solid modeling or 3D visualization instruments and methods. In someembodiments, the present invention provides a method of personalizing abiocompatible device produced by an additive manufacturing process. Insome embodiments, the present invention provides a method ofpersonalizing a skeletal orthopedic prosthesis or implant, a dentalprosthesis or implant or a soft tissue or hard tissue prosthesis orimplant. In some embodiments, the present invention provides a method ofpersonalizing a biocompatible device, wherein the biocompatible deviceis selected from a group consisting of the following: long bones,plates, intramedullary rods, pins, total joint prosthetics or portionsthereof, pelvic reconstruction prosthesis, cranial reconstructionprosthesis, maxillofacial reconstruction prosthesis, dental prosthesis,external fixation device for aligning long bones and the spine, slidingjoints, overlapping plates, external or implantable orthopedicintervention prosthesis, adjustable fixtures, internal Ilizarov devicesfor enabling the expansion or lengthening of long bones, implantablenon-orthopedic prosthesis for cardiovascular, neurological, digestive orinterventional implant devices for soft or hard tissue repair,cardiovascular stents, urological stents, interventional tools,interventional guides to assist accurate preparation of the tissue toenable the proper fit of the device, and instruments for laparoscopic,interventional, radiological, and minimally invasive procedures forcardiovascular, neurological, digestive applications in soft or hardtissues. In some embodiments, the present invention provides a method ofpersonalizing a biocompatible device manufactured from materialsselected from a group consisting of Cobalt-Chromium-Molybdenum (CoCrMo)alloy, Titanium alloy, commercially pure Ti (cpTi), medical gradestainless steel, Tantalum, Tantalum alloy, Nitinol, polymers, ceramics,oxides, minerals, glasses and combinations thereof. In some embodiments,the present invention provides a method of personalizing a biocompatibledevice, wherein the material is selected based on desirability ofbiomechanical properties and interaction with surrounding biologicalenvironment of the device. In some embodiments, the present inventionprovides a method of personalizing a biocompatible device produced usingat least two materials which are molecularly bonded through a gradientmelting process sequentially, regionally or in combinations thereof. Insome embodiments, the present invention provides a method ofpersonalizing a bone prosthesis primarily consisting of Ti6Al4V ELI(body of the device) in combination with CoCrMo for the articulatingfunction of the device using the gradient melting process. In someembodiments, the present invention provides a method of personalizing abiocompatible device, wherein the produced material is a Nitinol alloy,wherein further the device surface is substantially Ti for minimizing Nitoxicity. In some embodiments, the present invention provides a methodof personalizing a biocompatible device produced by additivemanufacturing technology and further produced with an element. In someembodiments, the element is a functional sensor, an optical element or astructural element. In some embodiments, the element is a MEMS lens,optical lens, ceramic whisker or a curved external fixture for Ilizarovdevice. In some embodiments, the present invention provides a method ofpersonalizing a biocompatible device which has mating surfaces for jointarticulation and whereby super alloys are deposited to certain regionsto minimize wear of these articulating surfaces. In some embodiments,the present invention provides a method of personalizing a biocompatibledevice which has internal structure or surface selected from a groupconsisting of honeycombs, struts, ribs, hollow, solid or combinationsthereof. In some embodiments, the present invention provides a method ofpersonalizing a supporting fixture for neck or spine trauma. In someembodiments, the present invention provides a method of personalizing acast or an articulation brace device with adjustability where range canbe slowly expanded. In some embodiments, the present invention providesa method of personalizing a surgical tool that fits hand and motionmechanics. In some embodiments, the present invention provides a methodof personalizing a biocompatible device, wherein the additivemanufacturing process is laser additive manufacturing, laser engineerednet shaping, selective laser sintering, electron-beam projectionlithography, direct metal deposition or electron beam melting. In someembodiments, the present invention provides a personalizingbiocompatible device produced by any of the methods described herein.

In some embodiments, medical devices are produced having a texturedsurface. This is particularly advantageous for orthopedic implants, asthe textured surface provides sites for ingrowth of natural bone, whichcan stabilize the device within the bone. An advantage of suchembodiments is that the use of cement or other adhesives or fillers canbe avoided.

The present invention provides methods, techniques, materials, systems,and devices and uses thereof for personalizing biocompatible implants,prosthetics and interventional tools for use on medical and veterinaryapplications. These and other objects and advantages of the presentinvention will become apparent from the detailed descriptionaccompanying the drawings.

BRIEF DESCRIPTION OF THE FIGURES

Various exemplary embodiments of the methods of this invention will bedescribed in detail, with reference to the following figures, wherein:

FIG. 1 illustrates a schematic of one embodiment of the presentinvention depicting general methodology used for creating personalizedmedical implants and prosthesis described in this invention (FirstEmbodiment of invention).

FIGS. 2A and 2B illustrate a detailed schematic of one method accordingto some embodiments as illustrated in FIG. 1 (First Embodiment ofinvention).

FIGS. 3A, 3B, 3C and 3D illustrate an embodiment of the presentinvention, wherein a series of 3D images and image reconstruction aregenerated from MRI images in order to provide implant devices forreconstruction of cranial defects. FIG. 3A is an MRI image of anosteosarcoma subject; FIG. 3B is a transverse section through theprospective implant site; FIG. 3C is a close up saggital view of theimplant site; and FIG. 3D is a front perspective view of the cranium.

FIGS. 4A-4D illustrate an embodiment of the present invention forproviding a personalized plate prosthetic for surgical repair. FIG. 4Ais an MRI image generated showing the site for a prospective prosthesis;FIG. 4B is a planned surgical resection profile image showing thevirtual fitting of the prosthesis in place; FIG. 4C shows the outline ofthe prospective prosthesis; and FIG. 4D represents the actual prosthesisin place.

FIG. 5 illustrates an embodiment of the present invention for providingan adjustable plate prosthetic for surgical repair. In this embodiment,the plate has two similar anchor ends that are adjustably connectedusing a slidable and fixable bridge.

FIG. 6 illustrates an embodiment of the present invention wherein theinvention provides an adjustable multiple plate prosthetic for surgicalrepair of the ilium.

FIG. 7 illustrates an embodiment of the present invention wherein theinvention provides a complex stent with multiple segments and multipleelements in each section.

FIGS. 8A-8C illustrate particular features of an artificial hip: FIG. 8Ais a conventional prosthetic hip including acetabular cup and integralball and stem; FIG. 8B is a personalized prosthetic hip with acetabularcup shaped to fit subject contours (as required due to disease, trauma,etc.), with standard integral ball and stem, and stem designed toprecisely fit subjects intramedullary space, femur contours, and have aspecific texture and/or material to improve bone interface; FIG. 8C is ahybrid prosthesis having a conventional prosthetic hip ball and stem buthaving a personalized adjustable length according to the invention.

FIG. 9 illustrates a schematic of one embodiment of the presentinvention depicting general methodology used for preparing a facilityand its' clinicians and/or practitioners to be able to use the systemsand devices described in this invention (Second Embodiment ofinvention).

FIGS. 10A and 10B illustrate a schematic of one embodiment of thepresent invention depicting general methodology used for creatingpersonalized medical implants and prosthesis described in this invention(Second Embodiment of invention).

FIG. 11 illustrates a detailed schematic of one method of patientqualification according to some embodiments as illustrated in FIG. 10(Second Embodiment of invention).

FIGS. 12A and 12B illustrate a detailed schematic of one method ofdevice design according to some embodiments as illustrated in FIG. 10(Second Embodiment of invention).

FIG. 13 illustrates a detailed schematic of one method of designcollaboration with clinicians according to some embodiments asillustrated in FIG. 10 (Second Embodiment of invention).

FIGS. 14A and 14B illustrate a detailed schematic of one method ofproducing device components according to some embodiments as illustratedin FIG. 10 (Second Embodiment of invention).

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS

The present invention provides methods, devices, systems, andinstruments related to medical implants and surgical instrumentsproduced for personalized fit and/or personalized function of individualusers. In particular, in some embodiments, the present inventionutilizes a combination of medical imaging; quantitative image analysis;computer aided design, manufacturing and engineering; telemedicine;virtual design collaboration, virtual design simulation and validation;informatics; mass-customization production; and additive manufacturingprocesses to personalize biocompatible devices for fit and/or function.This (non-prototype) production system is statistically controlledenabling the repeatability of the system to be probabilisticallyforecasted. The accuracy of features produced for medical implants andsurgical instruments may also be statistically controlled to enablemass-customization and speed of the overall system without jeopardizingproduct quality.

Embodiments of the systems and methods of the present invention providea number of unique features not present in medical practice today. Amongthese are a preliminary design and testing phase that permits a highlyvalidated design to be made based on patient-specific information.

Before the present methods are described, it is understood that thisinvention is not limited to the particular methodology and protocolsdescribed, as these may vary. It is also to be understood that theterminology used herein is for the purpose of describing particularembodiments only, and is not intended to limit the scope of the presentinvention.

Unless defined otherwise, all technical and scientific terms used hereinhave the same meanings as commonly understood by one of ordinary skillin the art to which this invention belongs. Although any methods andmaterials similar or equivalent to those described herein can be used inthe practice or testing of the present invention, the methods andmaterials of some embodiments of the present invention are describedherein. All publications mentioned herein are incorporated herein byreference for the purpose of describing and disclosing the devices,production methods, subjects in need, instruments, statistical analysisand methodologies which are reported in the publications which might beused in connection with the invention.

As used herein, “Subject” means mammals and non-mammals. “Mammals” meansany member of the class Mammalia including, but not limited to, humans,non-human primates such as chimpanzees and other apes and monkeyspecies; farm animals such as cattle, horses, sheep, goats, and swine;domestic animals such as rabbits, dogs, and cats; laboratory animalsincluding rodents, such as rats, mice, and guinea pigs; and the like.Examples of non-mammals include, but are not limited to, birds, and thelike. The term “subject” does not denote a particular age or sex. Insome embodiments, the subject is a patient for personalized orthopedicdevices or a surgeon for personalized surgical instruments.

The present invention provides methods, techniques, materials, systems,and devices and uses thereof for personalized fit and/or functionbiocompatible implants, prosthetics and interventional tools for use onmedical and veterinary applications. The devices produced according toembodiments of the invention are created by referencing a patientprofile (case) or, in the case of personalized surgical instruments, asurgeon profile. The devices are then produced using additivemanufacturing techniques based on a computer generated model such thatevery prosthesis or interventional device is personalized for the fitand/or function of the user having the appropriate material compositionand virtual validation of functional design for each use.

In some embodiments, the present invention provides a method ofpersonalizing a biocompatible device. This method comprises the steps of(a) obtaining a profile of the subject, including, for example, medicalhistory, imaging and genomic data, (b) producing a virtual 3D designmodel, wherein the virtual 3D design model is configured to parametersfrom the subject profile, and (c) producing a biocompatible device,wherein the biocompatible device is configured to the physicalspecifications of the virtual 3D design model. In this method, thedevice may be an implant, prosthesis or interventional tool.

In some embodiments, a potential subject for implantation of apersonalized biocompatible device is referred to an orthopedic surgeonfor evaluation (e.g. by another clinician). In some embodiments, apotential subject for implantation of a personalized biocompatibledevice is evaluated by an orthopedic surgeon (e.g. to determine if thepotential subject is a candidate for a personalized biocompatibledevice). In some embodiments, the present invention provides educatingorthopedic surgeons, physicians, nurse practitioners, nurses, andclinicians about the personalized biocompatible devices of the presentinvention. This education provides the user (e.g. surgeon, clinician,etc.) with the proper understanding of the personalized biocompatibledevices and their advantages over other devices such that they arecapable of recommending the device to potential candidates.

In some embodiments, the present invention provides collecting imagingdata of a subject. In some embodiments, the imaging data is used toprovide a detailed view of the subject (i.e., the particular region ofinterest on a subject). In some embodiments, the input imaging data maybe received from MRI, NMR, digital X-ray, CT or PET scanning of thesubject. In some embodiments, multiple input sources are used to providea detailed and specific view of the region of interest. In someembodiments, subject specific parameters (e.g. measurements, dimensions,and description of the area of interest (e.g. bone break)) are derivedfrom the imaging data. In some embodiments, parameters derived fromimaging data are sufficient to define the region of interest on thesubject in physical space (e.g. 3D space). In some embodiments, theimaging data is converted into a virtual model of the anatomy of thesubject. In some embodiments, the imaging data and subject specificparameters derived are sufficient to create a 3D model of the area ofinterest on the subject (e.g. a virtual model or a physical model or thesite of implantation). In some embodiments, the imaging data, subjectspecific parameters, subject genomic data, subject medical history, casedescription and/or other subject data are transferred to thedesign/production team. In some embodiments, a subject profile and casenumber are generated (e.g. based on and/or containing imaging data,subject specific parameters, subject medical history, case descriptionand/or other subject data).

In some embodiments, a virtual 3D design model is constructed of theregion of interest on the subject. In some embodiments, the virtual 3Ddesign model comprises a three-dimensional surface model of the regionof interest of the subject (e.g. bone of the subject). In someembodiments, a virtual 3D design model is constructed of thepersonalized biocompatible device. In some embodiments, the personalizedbiocompatible device is designed to fit with the existing bone of thesubject. In some embodiments, the personalized biocompatible device isdesigned to fit with the anatomy of the subject following surgicalalteration (e.g. cutting, grinding, or resection of bone etc.). In someembodiments, a preliminary exact fit model is produced (e.g. virtualmodel or physical model) comprising both the personalized biocompatibledevice and the region of interest on the subject (e.g. bone of subjectand implant). In some embodiments, the methods of calibrating, analyzingand constructing the solid modeling from input imaging data is performedthrough CAD, CAM, FEA of biological tissue of the subject, FEA ofmaterials, joint articulation simulation, solid modeling and/or 3Dvisualization instruments and related methods.

In some embodiments, a recommended resection profile (RRP) is generatedof the subject. In some embodiments, one or more data sources forcalculating a recommended resection profile (e.g. two data sources). Insome embodiments, CAD is used to determine the geometric variancebetween the healthy bone and the diseased bone. In some embodiments,healthy and diseased bone involves two regions (e.g. in the exemplarythe case of hemipelvectomy surgery it involves the left and rightpelvises). In some embodiments, determining a recommended resectionprofile uses CT voxel data (e.g. to determine the manifestation of thecancerous regions of the diseased bone through comparing the healthybone voxel density to the symmetrical cancerous bone). In someembodiments, curves from multiple data sources are combined to develop aresection profile. In some embodiments, for example, a curve identifyingthe geometrical differences between the healthy bone and the diseasedbone is combined with a curve identifying the voxel density differencesbetween the healthy bone and the diseased bone. In some embodiments, aplurality of data sources (e.g. curves) is merged into a single 3D nonuniform rational b-spline (NURBS). In some embodiments, the presentinvention provides information and insight to the surgical workflow. Insome embodiments, the surgeon or clinician is able to uniformly offsetthe recommended resection profile (RRP) by a constant amount (e.g. 1 mm,. . . , 5 mm, . . . , 10 mm, . . . , 20 mm, . . . , 50 mm, etc.) througha haptics graphical user interface, or draw on the model using a hapticsjoystick (e.g. to create a variable offset of the RRP based on his/herdiscretion).

In some embodiments, the present invention provides software packagesfor carrying out the steps of the invention (e.g. converting imagingdata into a model, model design, evaluating a virtual model, designing aCAS protocol, carrying out CAS, collaboration, production). In someembodiments, software for the present invention is custom designed. Insome embodiments, existing software and software packages can beutilized with the present invention. In some embodiments, existingsoftware and software packages are modified or combined with customsoftware to suit the uses of the present invention. In some embodiments,new software is developed and combined with existing or custom softwareto suit the use of the present invention.

In some embodiments, a personalized biocompatible device is evaluatedprior to the production of the physical device (e.g. for stability, fit,usefulness, longevity, stress to the device, stress to the bone). Insome embodiments, evaluating the device comprises device simulation,FEA, joint articulation simulation, surgical simulation, CAS, etc. Insome embodiments, evaluation of the device prior to production providescost and time savings. In some embodiments, evaluation of the deviceprior to production provides superior results following implantation. Insome embodiments, the biocompatible device is collaboratively evaluated(e.g. collaboration between the surgical team and the design/productionteam). In some embodiments the biocompatible device is evaluated forqualities including strength, durability, stiffness, compatibility withthe anatomy of the subject, shape, joint articulation, micromotion,bacterial strain, wear, etc. In some embodiments, following evaluation,revisions are made to the design of the biocompatible device. In thiscase, a new virtual 3D model can be produced, tested, and re-evaluated.In some embodiments, only following approval (e.g. collaborativeapproval (e.g. collaboration between the surgical team and thedesign/production)) is a design released to the personalizedbiocompatible device.

In some embodiments, the systems and methods employ a database ofhistoric intelligence to assist in design, production, and/or education.The historic intelligence, for example, includes correlations betweencertain patient profile information and certain design features andoutcomes. Through the monitoring of multiple patients and productdesigns over time, patterns may be detected that permit a new patientdesign to be optimized using historic intelligence from prior patientsthat had similar characteristics and achieved desired, optimal, ornon-optimal outcomes. The ability to generate and use a historicintelligence database is a unique feature of the individualized systemsand methods of the present invention.

Unlike prior systems and methods, embodiments of the present inventionprovide preliminary design analysis that involves the treatingphysician, but also considers the time constraints on the surgeon.Embodiments of the present invention permit the surgeons to be presentedwith a preliminary design that incorporates the patient profile data, aswell as, if desired, historical intelligence, and that has beenvalidated using methods described herein to qualify the device for usein the specific patient application based on solving the patient'sspecific problem(s). Without these features, the ability to solve thepatient-specific problem(s) is severely compromised or not possible.

In some embodiments, the personalized biocompatible device is producedby additive manufacturing process for producing the near-net-shapecomponent and state of the art subtractive manufacturing processes forfinishing the component. In some embodiments, the device may be askeletal orthopedic prosthesis or implant, a dental prosthesis orimplant or a soft tissue or hard tissue prosthesis or implant.

In some embodiments, production of the personalized biocompatible devicefurther comprises production of a 3D physical model of the device andthe implant location. In some embodiments, the physical model isproduced of a different material than the final device (e.g. lighter,lower cost, and/or easier to produce material such as plastic usingadditive manufacturing technology). In some embodiments, 3D models areused for patient education prior to surgical implantation of the device.

In some embodiments, the biocompatible device is selected from a groupconsisting of the following: long bones, plates, intramedullary rods,pins, total joint prosthesis or portions thereof, pelvic reconstructionprosthesis, cranial reconstruction prosthesis, maxillofacialreconstruction prosthesis, dental prosthesis, external fixation devicesfor aligning long bones and the spine, sliding joints, overlappingplates, external or implantable orthopedic intervention prosthesis,adjustable fixtures, internal Ilizarov devices for enabling theexpansion or lengthening of long bones, implantable non-orthopedicprosthesis for cardiovascular, neurological, digestive or interventionalimplant devices for soft or hard tissue repair, cardiovascular stents,urological stents, interventional tools, interventional guides to assistaccurate preparation of the tissue to enable the proper fit of thedevice, and instruments for laparoscopic, interventional, radiological,and minimally invasive procedures for cardiovascular, neurological,digestive applications in soft or hard tissues.

In some embodiments, a biocompatible device of the present inventionreplaces, interacts with, facilitates the use of, restores the functionor, and/or strengthens body systems, body regions and/or body parts of asubject including, but not limited to the head, mouth, neck, forehead,jaw, cheek, chin, upper limb, finger, thumb, hand, wrist, forearm,elbow, arm, shoulder, thorax, chest, rib cage, abdomen, groin, back,spine, spine components, vertebrae, sacrum, coccyx, intervertebraldisks, pelvis, perineum, lower limb, hip, buttocks, thigh, knee, leg,calf, ankle, foot, toes, musculoskeletal system, bones, cartilage,ligaments, tendons, circulatory system, digestive system, endocrinesystem, integumentary system (e.g. skin, hair, nails, etc.), lymphaticsystem, reproductive system, respiratory system, and urinary system. Insome embodiments, a biocompatible device of the present invention islimited to a subset of the above body systems, body regions, and bodyparts.

In some embodiments, the biocompatible device is produced from materialssuch as CoCrMo alloy, Titanium alloy, cpTi, Ti6Al4V ELI medical gradestainless steel, Tantalum, Tantalum alloy, Nitinol, polymers, ceramics,oxides, minerals, glasses and combinations thereof. Preferably, thesematerials are selected based on desirability of biomechanical propertiesand interaction with surrounding biological environment of the device.

In some embodiments, the device is produced using at least two materialswhich are produced sequentially, regionally, or combinations thereof. Asused herein, regionally indicates a large area of the prosthesis whereaslocally indicates a smaller region which is limited only be theresolution of the deposition process. In such instances differentlocalized regions can have two or more materials in specific desiredregions or location or large regions.

In some embodiments wherein two or more materials are used, the gradientof certain dissimilar materials may affect undesirable galvanicprocesses that can lead to corrosion or release of undesirable ions,thus such combinations are necessarily avoided.

In some embodiments, the device is a bone prosthesis and the productionmaterials are Ti6Al4V ELI in combination with cpTi. More preferably, theproduction material is Nitinol alloy, such that the device surface issubstantially made of Ti for minimizing Ni toxicity.

In some embodiments, the biocompatible device is produced by additivemanufacturing methods. Such methods are known in the art. For example,the field of additive manufacturing is the automatic construction ofphysical objects using solid freeform production (SFF). SFF or additivemanufacturing is a technique for producing near-net-shaped solid objectsby the sequential delivery of energy and material to specified points inspace to produce the solid. While the techniques of SFF share somesimilarities with techniques of rapid prototyping, rapid prototypingproduces only a prototype typically made of plastic polymer. However,the techniques of SFF allow for the integration of more powerful methodsof computer imaging and manufacturing techniques. Such techniquesinclude, but are not limited to, laser engineered net shaping (LENS),selective laser sintering (SLS), electron-beam projection lithography(EPL), electron beam melting (EBM), and direct metal deposition (DMD).In some embodiments, LENS uses a laser to melt metal powder and depositit on the device directly. In some embodiments LENS produces a part thatis fully solid and the metal alloy composition can be dynamicallychanged over the volume of the device. In some embodiments, SLS utilizesa laser to fuse powdered nylon, elastomer or metal. In some embodimentsSLS comprises a heat treating process called bronzed infiltration toproduce fully dense metal devices. In some embodiments EPL is similar toLENS and allows the device to be produced using a powdered metal alloyalong the leading edge which is sintered using an electron beam insteadof a laser. In some embodiments, EBM provides electrons which areemitted and projected at a powdered metal bed in which the molten metalis added layer by layer until the device is completed. In someembodiments, DMD is similar to LENS in that the desired alloy is added,in powdered form, directly to the substrate or biocompatible device andmelted by a laser beam such that the device is built up layer by layerin the size, shape and particular alloy content desired. In someembodiments, DMD, EPL, LENS and EBM afford the advantage that thecomposition, shape and texture of the product can be changed as thedevice is being produced. During additive manufacturing production, theprocess may be stopped such that an element may be added or the alloycomposition changed. Then the process may be followed by continuedadditive manufacturing. Further, it should be appreciated that using thedisclosed methods, the biocompatible device can be used such that theproduction materials are deposited regionally (e.g. an entire area ofthe implant) or locally (e.g. small areas that may be as small as theresolution of the instrumentation will allow) in some cases such areawill be on the order of a few microns to tens of microns depending onthe additive manufacturing process used.

In some embodiments, during production, the device is further enhancedwith an element feature. Such elements may include a functional sensor,an optical element or a structural element. In some embodiments, suchelements include a microelectromechanical system (MEMS) lens, opticallens, ceramic whisker or a curved external fixture for Ilizarov deviceor any other element that is not damaged by thermal, optical and otherconstraints posed by the additive manufacturing process and itsresolution limits.

In some embodiments, the biocompatible device has internal structure orsurface which can be solid or hollow or may include honeycomb, strut orribbed features, or combinations thereof.

In some embodiments, the biocompatible device may be a supportingfixture for neck or spine trauma. In some embodiments, the method ofpersonalizing a biocompatible device may be a personalized cast or anarticulation brace device having adjustability such that the range ofarticulation can be slowly expanded. In some embodiments, thebiocompatible device is a surgical tool that fits hand and motionmechanics.

In some embodiments, the invention provides a method of personalizing abiocompatible device, comprising the steps of: (a) quantitativelycalibrating a medical image; (b) analyzing the calibrated medical image;(c) compiling CAD of the analyzed and calibrated medical image; (d)creating CAM from the CAD data of step (c); (e) performing FEA ofbiological tissues of CAM from step (d); (f) performing FEA ofmaterials; (g) performing joint articulation simulation; (h) solidmodeling using 3D visualization instrumentation and virtual reality; and(i) producing the near-net-shape device using the additive manufacturingprocesses. In some embodiments, the additive manufacturing process usedis DMD, EPL, LENS, EBM, SLS or combinations as needed. In someembodiments, devices are produced by processes described above.

In some embodiments, the present invention comprises methods and toolsto produce implantable devices that will be personally fit to the formand function of individual subjects. In some embodiments, the inventionis implemented through a combination of technologies including medicalimaging (including CT, MRI, PET, digital X-ray, ultrasound and others),quantitative image analysis, CAD, CAM, FEA of biological tissues, FEA ofmaterials, joint articulation simulation, solid modeling, 3Dvisualization instrumentation and methods (virtual reality), andadditive manufacturing process that can directly produce high strengthimplants from biocompatible materials with much greater structural andgeometric design flexibility than conventional forging and “subtractive”machining methods. In some embodiments, the invention also comprisesmethods and devices for other medical devices including implants that donot require precise personalizing to subject data but nonethelessutilize the methods and tools described herein, methods to producesurgical tools and devices that are not implanted, and other relatedtechnologies that will be apparent to those skilled in the medical,material production, and other related arts.

In some embodiments, an exemplary personalized implant is generated asdescribed below:

In some embodiments, a 3D image data of the subject is obtained withdimensionally calibrated medical imaging instrumentation such as MRI andCT, and presented for clinical evaluation. Presentation can be providedvia virtual 3D display, multiple 2D sections, a solid 3D model, or acombination of these and other modalities.

In some embodiments, a clinical evaluation is made to determine thedesired morphology of areas to be surgically manipulated (e.g. areas ofinterest, ROI) such as re-aligned or resectioned, and an initialdetermination is made of how an implant will be shaped to make thenecessary reconstruction. Additional clinical data may also be used inthis determination, as appropriate, based on the best possible medicalpractice.

In some embodiments, the desired shape of the implant is evaluated withrespect to the intended surgical procedure based upon multiple factors.These include biomechanical FEA of tissue and FEA of implant material,mechanism for short-term and long-term tissue bonding and attachment,joint articulation simulation, desired surgical procedure, materialchoices, structural integrity, and the incorporation of anypre-engineered standard elements in the implant. Standard elements mayinclude articulation components (such as the ball and socket of aprosthetic hip joint), joinery to enable multiple sections of an implantto be assembled and attached during the surgical procedure, and designfeatures to enable the device to be adjusted in size or shape during theinitial implantation and at a future time post-implantation, if desired.

In some embodiments, the above designed implant is then evaluated by aclinician using dimensionally calibrated virtual 3D presentation methodsand/or solid models. Fit is checked, methods of attachment to healthytissues are evaluated, methods of assembly of implant components (ifmultiple components) are evaluated, and the entire surgical procedure isperformed “virtually” using 3D display and related methods and/or withsolid models. In some embodiments, if required, the above steps arerepeated until a final digital design and surgical plan are made.

In some embodiments, a final design of the implant is created digitally(e.g., via CAD) to precisely match the factors determined above. In someembodiments, a final design plan comprises overall shape, choice ofmaterial or materials, thickness and thickness gradients at alllocations, design of internal structures such as honeycombs, struts andvoids to provide ideal structural rigidity, placement of pre-engineeredstandard elements, surface materials (if different from bulk), surfacetexture, and any other necessary features. In some embodiments, thespatial resolution of the design is about 1 μm, 2 μm, 3 μm, 4 μm, 5 μm,6 μm, 7 μm, 8 μm, 9 μm, 10 μm, 11 μm, 12 μm, 13 μm, 14 μm, 15 μm, or 20μm to correspond with the manufacturing resolution and material handlingcapabilities of the direct manufacturing tooling and processes.

In some embodiments, the design created above is produced using CAMdigital methods such as additive manufacturing to produce the implantwith laser-based additive manufacturing technology and related methods.In some embodiments, production of each component is performed with thedesired material or materials directly from powdered metals (and certainother materials) that are delivered to the desired spatial location andthen laser annealed in place. This produces a very high strengthfine-grain structure, enables the production of internal features,enables layers of multiple materials, gradients of material properties,inclusion of ancillary internal elements, and produces resultantstructures that generally require minimal secondary machining usingsubtractive manufacturing technology.

In some embodiments, post-production processes are performed on theimplant. Grinding and polishing may be required for joining surfaces andfor bearing surfaces, such as in articulation joints. Additionalprocessing such as ion beam implantation or annealing may be performed,as required. In some embodiments, the surface texture resolution of thelaser-based additive free-form manufacturing process is about 1 μm, 2μm, 3 μm, 4 μm, 5 μm, 6 μm, 7 μm, 8 μm, 9 μm, 10 μm, 11 μm, 12 μm, 13μm, 14 μm, 15 μm, or 20 μm with no rough or abrupt transitions. It isthus intrinsically suitable for many tissue interfaces without furtherprocessing. In some embodiments, grinding and polishing are performed bymulti-axis grinding and polishing equipment.

In some embodiments, the device is then cleaned, sterilized, packed,labeled, and shipped to the clinic for the actual surgical applicationas was designed for using the virtual simulation.

In some embodiments, the production of the exemplary implant above isprovided as an example embodiment of the present invention and shouldnot be viewed as limiting the scope of the present invention.

In some embodiments, the present invention can be applied to implantableand other medical devices including the following:

Implantable Orthopedic Devices:

In some embodiments, personalized implantable devices may be created fora wide variety of clinical implants including skeletal orthopedicappliances for repair of long bones (including plates, intramedullaryrods, pins, and total joint prosthetics or portions thereof), pelvicreconstruction appliances, appliances for repair of cranial defects ordamage, maxillofacial repairs, dental prosthetics, and others that willbe apparent to those skilled in the art.

Prosthetic Devices:

In some embodiments, the methods described above may also be used forthe design, development, and production of personalized devices forexternal fixation, such as used for aligning long bones and the spine,and for generic or non-personalized devices intended for external orimplanted orthopedic intervention, and others that will be apparent tothose skilled in the art.

Soft Tissue Implant Devices:

In some embodiments, the methods described above may also be used forthe design, development, and production of personalized and genericdevices for implanted non-orthopedic applications such as forcardiovascular, neurological, gastrointestinal or other interventionalimplants used for soft or hard tissue repair.

Cardiovascular and Urological Stents:

In some embodiments, the methods described above may also be used forthe design, development, and production of advanced devices such asgeometrically complex cardiovascular and urological stents due to theunique capabilities of the design and production capabilities of thisinvention, and for other applications that will be apparent to thoseskilled in the art.

Interventional Tools:

In some embodiments, the methods described above may also be used forthe design, development, and production of interventional tools andinstruments such as required for laparoscopic, interventionalradiological, and minimally invasive procedures for cardiovascular,neurological, digestive or other applications in soft or hard tissue,and for other applications that will be apparent to those skilled in theart.

Surgical Instruments:

In some embodiments, the methods described above may also be used forthe design, development, and production surgical instruments having theergonomic and mechanical properties desired by the surgeon or otherend-user to create medical and other tools that will be morecomfortable, better weighted and have superior manipulating or cuttingsurfaces thereby providing superior performance.

In some embodiments, implantation of the personalized biocompatibledevice of the present invention is carried out by a surgical team (e.g.orthopedic surgical team). In some embodiments, implantation of thepersonalized biocompatible device makes use of CAS. In some embodiments,CAS removes and shapes the bone of the subject such that the boneprovides a precise fit for the personalized biocompatible device. Insome embodiments, the use of CAS by the surgical team provides precisefit of the implant with the anatomy of the subject. In some embodiments,the imaging data and modeling performed during steps of the presentinvention provide information required for precise CAS.

In some embodiments, a subject will require rehabilitation followingimplantation of the device of the present invention. Methods ofpost-surgical rehabilitation are well known to those of skill in theart. In some embodiments, a subject is monitored following surgery toanalyze the results of the implantation (e.g. monitored for 1 year, . .. , 5 years, . . . , 10 years, . . . , 25 years, . . . , 50 years). Insome embodiments, the actual implantation results are compared to devicesimulations performed during the implant design process. In someembodiments, differences between actual and simulated results are usedin improving design software, techniques, methods, algorithms, etc.

The following examples are related to devices and methods of the presentinvention and are put forth for illustrative purposes only. Theseexamples are not intended to limit the scope of the invention.

EXAMPLES Exemplary Embodiments

This Exemplary Embodiment and Examples I through IV describe a firstembodiment of the invention and examples V through XI describe a secondembodiment of the invention.

As shown in FIG. 1, in some embodiments, the present invention providesmethods and tools to produce implantable medical devices that willprecisely fit individual subjects. The present invention also comprisesmedical appliances and tools and implements designed and created throughthe disclosed process. In some embodiments, the invention is implementedthrough a combination of technologies including medical imaging(including CT, MRI, PET, X-ray, ultrasound, and others) and subjectconsultation (R1). Next, the product engineering configuration (R2)analysis is implemented using both behavioral modeling and ergonomicmodeling analysis. Next, virtual and/or physical prototyping isperformed (R3) which allows for validation of the product engineeringresults by further reference with (R1). Then, (R4) analysis of theimplant site identifies the friction area, analyzes the joint loadingand identifies material types that can or should be used in production.Next, (R5) additive manufacturing is performed using, in someembodiments laser engineered net shaping. However, other methods ofadditive manufacturing production can be used. Then, (R6) secondary,finishing, operations are performed such as cleaning and sterilizing isperformed. Then, (R7) quality assurance such as FDA compliance, materialcertification and dimensional certification is performed. Then, datadetermined in R7 is returned to the clinician confirming quality andsuitability of the device and the device is implanted. As shown,quantitative image analysis, CAD, CAM, FEA of biological tissues, FEA ofmaterials, joint articulation simulation, solid modeling, 3Dvisualization instrumentation and methods (virtual reality), andadditive manufacturing process can directly produce high strengthimplants from biocompatible materials with much greater structural andgeometric design flexibility than conventional forging and “subtractive”machining methods in which a larger piece of material is carved away ormachined down to arrive at the product. This invention also comprisesmethods and devices for other medical devices including implants that donot require precise personalization to subject data but nonethelessutilize the methods and tools described herein, methods to producesurgical tools and devices that are not implanted, and other relatedtechnologies that will be apparent to those skilled in the medical andmaterial production arts.

The following examples are provided:

Example Name Description I Image Provides a sample scenario of stepstaken Acquisition within the imaging, design and and collaborationportion of the process. Analysis (Primarily references FIGS. 2A and 2BSteps 1-33.) (First Embodiment) II Production Provides a sample scenarioof the steps involved in the production of the patient- specific device.(Primarily references FIGS. 2A and 2B Steps 33-35.) (First Embodiment)III Post-Production (First Embodiment) IV Applications of Describesexamples of the types of products Technology that this invention can beused to create. V Onboard New Provides a sample scenario of the stepsFacilities and involved in the preparation of facilities and Cliniciansclinicians that are new to the firm's invention so that they will beable to work with these methods, devices, systems, and instruments.(Second Embodiment) VI Provide Provides a sample scenario of the stepsPersonalized involved in the manufacture of personalized Implant toorthopaedic implants for specific patient Patient anatomy and function.(Second Embodiment) VII Patient Describes examples of the steps taken toQualification determine if a patient is an appropriate and candidate forthe devices manufactured in Characterization conjunction with thisinvention and the imaging work that is required in some embodiments.(Second Embodiment) VIII Design Patient- Provides a sample scenario ofthe steps Specific involved in the design of personalized Solutionorthopaedic implants for specific patient anatomy and function. (SecondEmbodiment) IX Pre-Surgical Provides a sample scenario of the stepsCollaboration involved in the collaborative review of the design for apersonalized orthopaedic implant for specific patient anatomy andfunction. (Second Embodiment) X Produce Device Provides a samplescenario of the steps Components involved in the production ofpersonalized orthopaedic implants for specific patient anatomy andfunction. (Second Embodiment) XI Long-term Periodical updates arecollected and entered in Monitoring the patient registry to documentsuccess rates. The results are used by the case-based reasoning systemfor future improvements to design parameters. (Second Embodiment)

Example I Image Acquisition and Analysis First Embodiment

As shown in FIGS. 2A and 2B, in some embodiments, the process startswith step S1 where the subject's demographic information is recorded andthe clinician makes a request for imaging, S2. 3-Dimensional image datais obtained from the subject S4 and presented for clinical evaluationwith the cooperation of multiple specialists, S3 and using the inventiondescribed herein (FIGS. 1 and 2A). This uses multiple steps as listed inTable 1, and further elaborated below.

TABLE 1 Image Acquisition and Analysis 1 CT/MRI Image calibration 2Calibration of laser surface contour scanning to determine surfacestructure as required for certain applications 3 Physical correlation ofpixel data for precise reconstruction of the subject's anatomicalstructure 4 In situ validation 5 Establish protocol for imageacquisition and transport 6 Troubleshooting of various imagingparameters - SIze, intensity, orientation, spacing, etc. 7 Image fileformat, size, and transport medium 8 Image/subject database 9 Integratewith CAOS (computer assisted orthopedic surgery) system, as appropriate10 Perform Image reconstruction 11 NURBS interpolation of boundarypoints 12 Contour based reconstruction for semi-parametric CAD modeling13 Point-cloud reconstruction for explicit CAD modeling 14 Morphing forimplant fitting/sizing/design revision 15 3D surface and solid modelingof internal features 16 Export to IGES/STL format for FEA and CAM 17Cross-calibration across imaging/CAD/CAM systems 18 Data acquisition andreduction

Image Calibration:

In some embodiments, a multimodality deformable phantom is constructedto calibrate and validate the imaging system's ability to preciselycapture the physical dimension of a 3D object in various view areas. Thephantom consists of sets of 3D markers with known physical dimension andlocations. The fiducial markers (Region of Interest (ROI) S7 areidentified on the image yielding their voxel coordinates which are usedto calculate the marker distances and polygonal areas in comparison withthe physical measurements obtained from a 3D laser surface scanner anddigital calipers. Image calibration coefficients are estimated using aleast square algorithm. Furthermore, after 3D reconstruction of thephantom model from the images, axial calibration is conducted forcalibrating the marker axial distance and volume in comparison with thephysical measurements obtained from a 3D laser surface scanner anddigital calipers. Imaging parameters are also calibrated to attain theminimum resolution of the imaging system. For accurate replication ofthe subject-specific anatomy further onsite calibration is done bysimultaneously imaging a smaller scale phantom while the subject imagesare acquired, SS. After the region of interest is identified, then thesubject and other clinical personnel participate in discussion of theavailable therapeutic technique/intervention necessary (S8-S 10). Thisis followed by a determination of the required surgical operations andspecifications, S11. The data is then transferred to the radiologistsand bio-imaging personnel, S12/S13.

Surface Reconstruction:

In some embodiments, a series of the calibrated images are thensegmented (S14) and registered (S15). An image is segmented first bydividing it into different regions of homogeneous properties. Eachanatomic component (class) is classified into separating surfaces asdefined by discriminant functions. After a finite number of unstructuredboundary points are computed (S 16) in a slice through the segmentationprocess, curve fitting using cubic splines or non-uniform rationalB-splines (NURBS) S17, is done with the boundary points to generateboundary curves (S 17) of each anatomic component for further geometricreconstruction. Subsequently, for surface modeling and 3-D geometricreconstruction lofting operation is done with a series of the refittedboundary curves (BCs), S20. In addition once the image is displayed theimage is validated, S19, using collaboration software. Following thedisplay of the 3-D solid models, S20, the model is validated by theclinician, S21 and the displayed 3-D solid model is exported to theengineering personnel for final design of the device which includesfinite element analysis and human motion simulation S23.

Clinical Evaluation:

In some embodiments, clinical evaluation is made to determine thedesired morphology of areas to be resectioned and an initialdetermination is made of how an implant will be shaped to make thenecessary repair. Additional clinical data may also be used in thisdetermination, as appropriate based on the best possible medicalpractice. Multiple data sources for may be used for calculating arecommended resection profile. In some embodiments, CAD is used todetermine the geometric variance between the healthy bone and thediseased bone. In some embodiments, MRI pixel data is used to determinethe manifestation of diseased or damaged bone through comparing thehealthy bone pixel density to the symmetrical damaged or unhealthy bone(e.g. cancerous or broken). In some embodiments, curves from multipledata sets are merged into a single three dimensional non uniformrational b-spline (NURBS). The surgeon, through the haptics graphicaluser interface is able to offset the recommended resection profile (RRP)by a constant or variable offset of the RRP based on his/her discretion.In some embodiments, additional clinical information includes subjecthistory for relevant parameters including a complete medical historywith emphasis on factors that alter strength of tissues such as generalhealth, anthropometric measures such as height and weight, activity,skeletal and connective tissue health factor including bone density, andothers that are critical for application. (FIG. 2, 3A-3D).

In some embodiments, the transfer of information to and from surgeon(S21-S23) is ideally performed with a virtual 3D digital model ofsubject data that is calibrated for image spatial/spectral resolutionand processed to accurately replicate the physical dimensions of thesubject-specific anatomical structures. This dataset is transmittedelectronically to the clinician who is able to manipulate the digitalmodel dynamically in order to view any necessary aspect of thestructure. Using collaboration software such as for example, Microsoft®Live Meeting (Microsoft, Redmond, Wash.) the surgeon then marks the areafor any necessary clinical manipulation such as excision, and labelsadditional areas such as desirable locations for attachment of theprosthetic, regions that must be left alone, and provides otherannotations regarding the surgical procedure and factors that should beaddressed in the design of the final implant. This data is thencommunicated, digitally in some embodiments, back to the manufacturingfirm, S24, where further evaluation and design is performed. In caseswhere surgeons are not comfortable with virtual 3D digital model, orwhere such computational and visualization hardware is not available,the surgeon can receive a dimensionally calibrated physical replica ofthe 3D digital model (S20-22) of a polymer or other material that isthen manually marked by the surgeon (S21).

Implant Design Based on Clinical Evaluation:

In some embodiments, the desired shape of the implant is evaluated withrespect to the intended surgical procedure based upon multiple factors.These include biomechanical Finite Element Analysis (FEA) of tissue andFEA of implant material, S25, mechanisms for short-term and long-termtissue bonding and attachment, desired surgical procedure, materialchoices, and the incorporation of any pre-engineered standard elementsin the implant, S26. Finite Element Analysis is well known in the artand is a computer simulation technique in which the object isrepresented by a geometrically similar model consisting of multiple,linked, simplified representations of discrete regions or finiteelements on an unstructured grid. See, for example, Finite ElementMethods for Structures With Large Stochastic Variations, Elishakoff, 1.and Ren, Y, 2003; Finite Element Methods With B-Splines, Hollig, K.,2003. Standard elements may include articulation components (such as theball and socket of a prosthetic hip joint), joinery to enable multiplesections of an implant to be assembled and attached during the surgicalprocedure, and design features to enable the device to be adjusted insize or shape during the initial implantation and at a future time postimplantation, if desired. FEA provides a mathematical method to solvethe limitations of the implant based on the geometric design andmaterial type used, S27.

In some embodiments, the general fit of the device is designed based onthe shape of the tissue it will interact with, as primarily determinedfrom the CT, MRI, PET, X-ray, ultrasound, and related calibrated medicalimaging data. In addition, for some tissues such as maxillary, facialand skull reconstruction where external appearance is critical,quantitative external imaging and shape scanning are used to obtain goodesthetics using 3-D laser surface scanners (FIG. 4), S27.

In some embodiments, materials used in the device are chosen forbiocompatibility such as metal alloys commonly used in medical devicesincluding CoCrMo, Titanium alloys and commercially pure Ti (cpTi),medical grade stainless steels, tantalum and tantalum alloys, and othersincluding included ceramics and oxides that can be incorporated into thedesign. The regions that will adhere to bone, when desirable, may beformed of cpTi to enhance bone attachment, and/or incorporate specific3-D textures, modulus, other materials (such as oxides, minerals,glasses) or incorporate other properties to promote bone attachment andingrowth that are known in the art.

In some embodiments, the material and device-bone material interface canbe different in different locations, such as to provide differentinterfaces with cortical and cancellous bone to alter attachment andlocal biomechanical interaction. Finite element analysis mechanicalsimulations of tissues and the implant (S24-S30) are used to optimizethe interaction to provide best possible function and minimize stressshielding. In addition to variations of the prosthetic material and thematerial thickness, internal material structures such as honeycombs,struts or ribs may be designed in to tailor the local and the globalbiomechanics of the device. Table 2 outlines the methodology for FEAsimulation.

TABLE 2 1 FE model generation 2 Pre and post-operative conditions 3Optimum selection of element type and size 4 Mesh optimization forconvergence 5 Material properties 6 Image based assessment 7 Noninvasiveonsite testing 8 Solution 9 Linear vs. nonlinear 10 Functionalassessment and validation

In some embodiments, as required for an application, the implant may bedesigned in multiple components. For example, it is clinically desirableto bridge or surround ligament attachments that are otherwise healthyfor reconstruction of a diseased or traumatized pelvis. Separate,attachable, components of the implant are then designed to surround suchstructures, and the components are then assembled and attached asnecessary in surgery. FIG. 5 represents an implant 20 having opposinganchor ends 22 that are adjustably connected using a sliding bridge 24.In use, such an implant may be used to reconstruct the traumatizedpelvis FIG. 6. In some embodiments, the two anchor ends are producedaccording to the data obtained using MRI and CAT images as discussedabove and shown in FIG. 3A-D. The anchor ends 22 are put in place,spanning the damaged area and the bridge 24 holds the anchors ends 22together. Further, it should be appreciated that using the methodsdescribed herein, the anchor ends (or any other part of the device) maybe constructed with variable thickness and shape to best fit the pelvictissue and provide the appropriate biomechanical properties.

In some embodiments, the design of the implant will allow onsiteadjustments, where feasible and desirable, since even the best solidmodel will not always be a perfect representation of the tissue exposedduring surgery. This will enable the surgeon to make necessaryadjustments during the procedure. In part this may be due to theimperfect tools and especially relatively coarse method of hand-heldburrs and other tools used to remove bone during surgery. As required,specific tools and guides can also be designed and produced to assisttissue preparation.

In some embodiments, the ideal method to attach an orthopedic prosthesisis determined through anatomic and biomechanical evaluation of thehealthy bone. Analysis will determine the best locations, bestorientation angles with respect to loading, and related biomechanicalanalyses. Conventional bone-screw technology may be used by the surgeonto make this attachment. Multiple locations for bone-screws will enablethe surgeon to determine the optimum choices during the procedure toensure attachment to high strength bone. As needed, a biomechanicalanalysis of alternate screw locations may be provided to the surgeon.Flanges and wings may be used to support less strong areas with thincortical bones and/or remarkable trabecular bones, while flanges on bothsides of a structure with a thru connection can provide solid anchoringwhen required. Fitting the device in place may be accomplished withplates that bridge prosthesis with remaining tissue. Such plates can beprovided in several sizes when adjustability may not be possible orprovide sufficient range.

In some embodiments, as required for a specific application, theprosthetic may be designed with intrinsic adjustability to alter the fitduring surgery using features such as sliding joints (e.g. slidingdovetails) or overlapping plates (FIGS. 5 and 6), S28. Such features mayalso be used to alter fit post surgery if required due to growth orother factors or needs. Such an adjustable fixture includes an internalIlizarov device to enable the expansion or lengthening of long bones.Access to the adjusting structure is designed so that such alterationsare made with minimal surgical trauma, such as minimally invasively.

Evaluation of Designed Implant by Clinician:

In some embodiments, the implant design is evaluated by the clinician,S29, using virtual 3-D presentation methods and/or solid models asillustrated in FIGS. 3A-3D and 4A-4D. Fit is checked, methods ofattachment to healthy tissues are evaluated, methods of assembly ofimplant components (if multiple components) are evaluated, and theentire surgical procedure is performed “virtually” using 3-D display andrelated methods and/or with solid models. If required, steps 3 and 4shown in TABLE 2 and steps S25-S29 (FIG. 2B) are repeated until a finaldigital design and surgical plan are made, S30.

In some embodiments, the final design of the implant is createddigitally using CAD solid modeling to precisely match the factorsdetermined above, S31. This includes the overall shape, choice ofmaterial or materials, thickness and thickness gradients at alllocations, design of internal structures such as honeycombs to provideideal modulus, placement of pre-engineered standard elements, surfacematerials (if different from bulk), surface texture, and any othernecessary features. The spatial resolution of the design is ˜10 μm tocorrespond with the manufacturing resolution and material handlingcapabilities of the direct manufacturing tooling and processes.

In some embodiments, pre- and post-operative clinical and biomechanicalassessments are made for functional assessment of the custom implants.Clinical evaluations include joint range of motion and strength testing.For biomechanical assessment finite element analysis simulations areused to develop models with the implant in-situ. Various loadingconditions are tested to predict stress localization in the interfaceand stress shielding. Model parameters are obtained from the image dataand material testing of biopsy specimens harvested during surgery, S30.

In some embodiments, pre- and post-operative clinical and biomechanicalassessments are made for functional assessment of the custom implants.Clinical evaluations include joint range of motion and strength testing.For biomechanical assessment finite element analysis simulations areused to develop geometric CAD solid models with the implant in-situthrough virtual surgical operation simulating the actual surgery done tothe subject. A number of 10 noded 3D tetrahedral elements are used tocreate finite element meshes of the geometric models. Mesh convergenceanalysis is conducted for accurate simulations. Various loadingconditions as obtained from the literature and pre- and post-operativefunctional testing of the subject are tested to predict stresslocalization in the interface and stress shielding. Model parameters areobtained from the image data and material testing of biopsy specimensharvested during surgery. A linear static analysis is conducted toobtain first-order solutions. As needed, more sophisticated analysissuch as nonlinear and transient analyses are conducted to reflect thelevel of physical activities of the subject. The simulation results arecross-validated with those from the pre- and post-operative functionaltesting and further biomechanical assessments are done accordingly.

Example II Production First Embodiment

In some embodiments, the design created above is produced using directcomputer aided manufacturing (CAM) digital methods to produce theimplant with laser-based additive free-form manufacturing as describedabove, S33. In some embodiments, production of each component isperformed with the desired material or materials directly from powderedmetals (and certain other materials) that are delivered to the desiredspatial location and then laser annealed in place (using, for example,DMD, LENS or the like) or annealed using an electron beam (EBM). Thisproduces a very high strength fine-grain structure, enables theproduction of internal features, enables layers of multiple materials,gradients of material properties, inclusion of ancillary internalelements, and produces resultant structures that generally requireminimal post-production processing.

In some embodiments, multiple materials are applied sequentially,locally, and in specific locations, if required to achieve desiredproperties For example, the bone interface aspect of a bulk Ti6 implantcan be produced with cpTi to enhance bone bonding, or a gradient ofmaterials may be created to affect galvanic processes.

In some embodiments, Nitinol (NiTi) shape-memory alloy structures areentirely Ti on the surface to minimize Ni toxicity.

In some embodiments, and as desired during the additive manufacturingapproach, the process is stopped and an element added, followed bycontinued additive manufacturing. Such elements can include functionalsensors such as MEMS devices including, but not limited to, neuronal,neuromuscular or skeletal stimulators, optical elements such as lens,structural elements such as ceramic whiskers, or other elements toprovide functional or other capabilities. Any material or device can beincorporated that is not damaged by the thermal, optical and otherconstraints posed by the laser or electron additive manufacturingprocess, and in consideration of the laser or electron additivemanufacturing process resolution limits.

Example III Post Production First Embodiment

In some embodiments, necessary post production processes are performedon the implant. In some embodiments, post production processes includesubtractive manufacturing processes for finish machining operations,grinding and polishing as may be required for joining surfaces and forbearing surfaces, such as in articulation joints, etc. Additionalprocessing such as ion beam implantation or annealing may also beperformed may be performed. The surface texture resolution of theadditive manufacturing process is currently ˜10/μm with no rough orabrupt transitions. It is thus intrinsically suitable for many tissueinterfaces without further processing. For example, this texture limitcan enable the direct production of tissue interfaces with features thatmay be as small as 10/μm, or larger features as desired in order toenhance tissue interactions such as bone growth into the implant. Otherpost production processes include ion beam implantation, as is routinelyused to harden bearing surfaces in prosthetic knees and hips, as well asannealing and other thermal treatments to affect material structure.

Preparation for Transport and Clinical use

After the production processes the device is then cleaned, sterilized,packed, labeled, and shipped as necessary for the actual surgicalapplication, S34/S35 where the process ends.

Example IV Applications of Technology

In some embodiments, using the methods and technology described above,personalized implantable devices may be created for a wide variety ofclinical implants including skeletal orthopedic appliances for repair oflong bones (including plates, intramedullary rods and total jointprosthetics or portions thereof), pelvic reconstruction appliances,appliances for repair of cranial defects or damage, maxillofacialrepairs, dental prosthetics, and cosmetic enhancements, others that willbe apparent to those skilled in the art.

In some embodiments, a unique feature of this invention is designed-inintrinsic adjustability to alter the fit during surgery using featuressuch as sliding joints (e.g. sliding external or internal dovetails) oroverlapping plates (FIGS. 5-8). Such features may also be used to alterfit post-surgically if required due to growth or for therapeutic reasonssuch as with an internal Ilizarin device. Access to the adjustingstructure can be planned so that such alterations can be made withminimal surgical trauma, such as minimally invasively or even withoutinvasion using an implanted actuator controlled remotely by an externalsignal (such as radio frequency control), or directly by percutaneoustransmission (such as via momentarily or long term inserted controllines).

In some embodiments, the methods described above may also be used forthe design and development of personalized devices for externalfixation, such as used for aligning long bones and the spine, and forgeneric or non-personalized devices intended for external or implantedorthopedic intervention, and others that will be apparent to thoseskilled in the art.

In some embodiments, the unique capabilities of the design andmanufacturing process enable multiple elements to be incorporated inmonolithic structures, internal features of virtually any desiredgeometry, and the creation of shapes that are not readily created withother methods such as complex curves and sliding joints.

In some embodiments, an application of a complex device is a curvedexternal fixture for an Ilizarov device. Other applications includesupporting fixtures for neck or spine trauma that accurately fit thesubject, and personalized casts and articulation brace devices withadjustability so that range of mobility can be slowly introduced asrequired for physical therapy.

In some embodiments, the methods described above may also be used forthe design and development of personalized and generic devices forimplanted non-orthopedic applications such as for cardiovascular,neurological, digestive or other interventional implants used for softor hard tissue repair. The method allows superior devices to be made,such as, for example, geometrically complex stents (FIG. 7) due to theunique capabilities of the design and production invention describedabove, including, but not limited to produce devices having varyingalloy content, the ability to include honeycombs-shaped internalstructures, hollow internal structures, full or partial rib internalstructures, struts, wings and other complex features not possible usingconventional subtractive machining technology, such as for example,functional elements such as sensors, actuators, stimulators and thelike, and for other applications that will be apparent to those skilledin the art.

In some embodiments, the unique capabilities of the design andmanufacturing process enable multiple elements to be incorporated inmonolithic structures, internal features of virtually any desiredgeometry, and the creation of shapes that are not readily created withother methods. Examples include stents of any shape, with spatiallyvariable material flexibility, and expandability. Other examples includestaples, clips, pins and other devices to effect tissue closure orpositioning, cases for devices such as pacemakers and other encapsulatedelectronics, sensors, and actuators, dimensionally complex multiplematerial (as required) detection and stimulation electrodes,neuro-stimulators and sensors, and valve prosthetics, and componentssuch as stents (frames) used in tissue valves.

In some embodiments, the methods described above may also be used forthe design and development of interventional tools and instruments suchas required for laparoscopic, interventional radiological and minimallyinvasive procedures for cardiovascular, neurological, digestive or otherapplications in soft or hard tissue. Using this invention, superiordevices may be made such as geometrically complex cardiovascular,urological and biliary stents (FIG. 7) due to the unique capabilities ofthe design and production capabilities of this invention. Moreover, thedesign capabilities for fitting structure and biomechanics to achieveoptimal devices can also be applied to the physician using these devicesin order to create medical and other tools that will be more comfortableand thus provide superior performance by anatomic and biomechanicalfitting of the device to the user and to the necessary motion used forthe procedure.

In some embodiments, the invention can be used to create hybridprosthetic devices such as, for example, artificial hips. In someembodiments, illustrated in FIGS. 8A-C, the invention can be used tocreate a prosthesis that is designed to fit into the subjects existingskeletal architecture. FIG. 8A illustrates a conventional prosthetic hipincluding acetablular cup 32 and integral ball 34 and stem 36. FIG. 8Billustrates a personalized prosthetic hip with acetablular cup 42 shapedto fit subject contours (as required due to disease, trauma, etc.), withstandard integral ball 44 and stem 46, with the stem 46 designed asdescribed and illustrated in FIG. 3 to precisely fit the subject'sintramedullary space, femur contours, and have a specific texture and/ormaterial to improve bone interface. FIG. 8C illustrates conventionalprosthetic hip ball 34 and stem 36 with adjustable bridge 48 between(otherwise conventional) ball and stem. In this example, the fasteningdevice, such as, a pin or screw to lock position is not shown.

In some embodiments, the unique capabilities of the design andmanufacturing process enable multiple elements to be incorporated inmonolithic structures, internal features of virtually any desiredgeometry, and the creation of shapes that are not readily created withother methods. This includes (1) curved tubes with telescoping elementsand multiple lumens; (2) stents and other devices that do not requirelaser cutting with consequent production of sharp edges; (3) shapes thatare not readily produced with conventional machinery including wallthicknesses, bifurcations, element spacing, inside and outsidediameters, and extensibility that vary along length; and (4) materialsthat include composites of multiple metals.

It is recognized that modifications may be made by one of skill in theart of the invention without departing from the spirit or intent of theinvention and, therefore, the invention is to be taken as including allreasonable equivalents to the subject matter of the appended claims.

Example V Onboard New Facility and Clinicians Second Embodiment

In some embodiments, using the methods and technology described hereinand based on FIG. 9, a facility and/or the practioners therein, willneed to be Onboarded. That is to say that they need to be knowledgeablein and be prepared to provide the methods, devices, systems, andinstruments related to medical implants and surgical instrumentsproduced for personalized fit and/or personalized function of individualusers.

In some embodiments, facility-based components including instruments andtechnology will need to be implemented. The new facility and thepractitioners will need to be configured into various automated systems.

In some embodiments, various technical and procedural interfaces betweenfacility and the company need to be established.

In some embodiments, in the beginning and repeated as necessary,orthopaedic surgeons and other clinicians and technicians are educatedas follows:

-   -   learn how to engage the herein described process    -   gain knowledge in the advantages of personalized fit and/or        function    -   gain knowledge in the various technologies and applications used        within the herein described process    -   learn collaboration approach to design    -   experience intuitive and easy-to-use graphical user interface    -   understand haptics (computer simulation of the sense of touch)        device

Example VI Provide Patient with Personalized Device Second Embodiment

A driving principles behind the processes and methods are to utilize acollaborative approach that includes the expertise of the surgeon in thedesign, incorporate advanced manufacturing technology formass-production (adaptive machining) and implant validation, and producecost-effective, patient-specific implants in 48 hours or less.

In some embodiments, using the methods and technology described herein,and based on FIGS. 10A and 10B, the process begins with the presentationof orthopaedic-related pain to an Orthopaedic Surgeon and ends with therehabilitation following implant surgery. The surgeon qualifies thepatient and collects data and images which are sent to the manufacturingfirm where a new case is created. A patient-specific solution isdesigned and then presented to the surgeon for pre-surgicalcollaboration.

In some embodiments, following design authorization, an order for allDevice Components and an optional physical model is created. The termDevice has referred to the primary device to be implanted (e.g., hip,knee) but typically includes the collection of all Device Components. AComponent could be the Device (e.g., trauma plate), or a part of aDevice (e.g., ball and socket), or a surgical tool (e.g., Cutting Tool)or other part (e.g., Screw) used to implant the Device. Uponauthorization of the Device Design, an order for the production and/oracquisition of all Device Components that are required for thisparticular patient (and surgeon) is created. The entire Order is managedthrough the entire Production process.

In some embodiments, per the Patient Order, all required components areproduced and/or acquired and the entire order is shipped, in someembodiments, within 48 hours of the Order being placed. Deviceimplantation takes place, success is verified and rehabilitation isprovided.

Example VII Patient Qualification and Characterization Second Embodiment

In some embodiments, using the methods and technology described hereinand based on FIG. 11, a patient is qualified as an appropriate candidatefor a personalized implant.

Record Patient Medical History, 1.1: In some embodiments, the subject'sphysical data, genomic data and medical history information arerecorded, including medical imaging data, age, genetic diseasepredisposition, allergies, potential exposure to bacteria strains(soldiers in Iraq and Afganistan), and pre-treatment activity level.

Request & Schedule Imaging, 1.2: In some embodiments, some imagesrequire advanced scheduling. The clinician must request specifics forwhat is to be imaged and determine the type of 3D imaging (CT, MRI, PET,digital X-ray, ultrasound, and others). The clinician should establishimaging parameters like size, intensity, orientation, spacing, etc. andidentify the region of interest for imaging.

Capture 3D Images, 1.3: In some embodiments, three-dimensional imagedata is obtained from the subject. The image is calibrated forengineering use during design.

In some embodiments, a multimodality deformable phantom is used tocalibrate and validate the imaging system's ability to precisely capturethe physical dimension of a 3D object in various view areas. The phantomcomprises sets of 3D markers with known physical dimension andlocations. The fiducial markers (Region of Interest (ROI)) areidentified on the image yielding their voxel coordinates which are usedto calculate the marker distances and polygonal areas in comparison withthe physical measurements obtained from a 3D laser surface scanner anddigital calipers. Image calibration coefficients are estimated using aleast square algorithm. Furthermore, after 3D reconstruction of thephantom model from the images, axial calibration is conducted forcalibrating the marker axial distance and volume in comparison with thephysical measurements obtained from a 3D laser surface scanner anddigital calipers. Imaging parameters are also calibrated to attain theminimum resolution of the imaging system. For accurate replication ofthe subject-specific anatomy further onsite calibration will be done bysimultaneously imaging a smaller scale phantom while the subject imagesare acquired.

Evaluate data and images, 1.4: In some embodiments, three-dimensionalimage data is presented for clinical evaluation with the cooperation ofmultiple specialists. After the medical imaging is evaluated, thesubject and other clinical personnel participate in discussion of theavailable therapeutic technique/intervention necessary.

Determine Surgical Plan, 1.5: In some embodiments, a determination ofthe required surgical operations and specifications is made. If thepatient is a candidate for a personalized device from the firm, then thePatient Case Profile data and images (“Case Material”) are then preparedand transferred to the firm.

Example VIII Design Patient-Specific Device Second Embodiment

In some embodiments, using the methods and technology described hereinand based on FIGS. 12A and 12B, a patient-specific solution is designed.

Segment and Register Calibrated Images, 3.1: In some embodiments,imaging data is verified, confirming acquired full region of interest,correct location, and correct size. A series of the calibrated imagesare then segmented and registered. Segmenting data identify relevantanatomical features. An image is segmented first by dividing it intodifferent regions. A finite number of unstructured boundary points arecomputed in a slice through the segmentation process. Each anatomiccomponent (class) is then classified into separating surfaces.

Surface Reconstruction, 3.2: In some embodiments, after a finite numberof unstructured boundary points are computed in a slice through thesegmentation process, a surface is created.

Create Anatomic Solid Model, 3.3: In some embodiments, an‘unintelligent’ or non-parametric model is created from CT and MRI data.A parametric model is then created from the non-parametric model. Curvefitting is performed to create solid models. This may include usingcubic splines or NURBS with the boundary points to generate boundarycurves of each anatomic component for further geometric reconstruction.Subsequently, for surface modeling and 3D geometric reconstructionlofting operation is done with a series of the refitted boundary curves.

Plan Device Fixation, 3.4: In some embodiments, an engineer decides howthe device will be attached to the bone (e.g., the degree of press fit)based on quality of preserved bone, patient profile variables andcase-based reasoning intelligence. The regions that will adhere to bone,when desirable, may be formed of cpTi to enhance bone attachment, and/orincorporate specific 3D textures, modulus, other materials (such asoxides, minerals, glasses) or incorporate other properties to promotebone attachment and ingrowth that are known in the art.

In some embodiments, the general fit of the device is designed based onthe shape of the tissue it will interact with, as primarily determinedfrom the CT, MRI, PET, digital X-ray, ultrasound, and related calibratedmedical imaging data. In addition, for some tissues such as maxillary,facial and skull reconstruction where external appearance is critical,quantitative external imaging and shape scanning are used to obtain goodesthetics using 3D laser surface scanners (FIG. 4). In some embodiments,multiple data sources may be used for calculating a recommendedresection profile (RRP). In some embodiments, CAD is used to determinethe geometric variance between the healthy bone and the diseased bone.In some embodiments, CT voxel data is used to determine themanifestation of diseased or damaged bone through comparing the healthybone voxel density to the symmetrical damaged or unhealthy bone (e.g.cancerous or broken). In some embodiments, curves from multiple datasets are merged into a single 3D NURBS. Robotic surgery is simulated forthe resection profile.

In some embodiments, the ideal method to attach an orthopedic prosthesisis determined through anatomic and biomechanical evaluation of thehealthy bone. Analysis determines the best locations, best orientationangles with respect to loading, and related biomechanical analyses.Conventional bone-screw technology may be used by the surgeon to makethis attachment. Multiple locations for bone-screws will enable thesurgeon to determine the optimum choices during the procedure to ensureattachment to high strength bone. As needed, a biomechanical analysis ofalternate screw locations is provided to the surgeon. Flanges and wingsmay be used to support less strong areas with thin cortical bones and/orremarkable trabecular bones, while flanges on both sides of a structurewith a thru connection can provide solid anchoring when required.Fitting the device in place may be accomplished with plates that bridgeprosthesis with remaining tissue. Such plates can be provided in severalsizes when adjustability may not be possible or provide sufficientrange.

Design Device, 3.5: In some embodiments, all components of the deviceand all surgical tools are designed. A parametric model (intelligent,virtual, solid model) is created and is dependent on an anatomic modeland may take certain features from it.

In some embodiments, following the display of the 3D solid models aninitial device is designed referencing the imaging software and thesuccesses and failures of past devices based on the case-based reasoningsystem.

In some embodiments, multiple data sources are used for calculating arecommended resection profile (RRP). In some embodiments, CAD is used todetermine the geometric variance between the healthy bone and thediseased bone. In some embodiments, CT voxel data is used to determinethe manifestation of diseased or damaged bone through comparing thehealthy bone voxel density to the symmetrical damaged or unhealthy bone(e.g. cancerous or broken). In some embodiments, curves from multipledata sets are merged into a single 3D NURBS.

In some embodiments, materials used in the device are chosen forbiocompatibility such as metal alloys commonly used in medical devicesincluding CoCrMo, Titanium alloys and cpTi, medical grade stainlesssteels, tantalum and tantalum alloys, and others including polymers,ceramics and oxides that can be incorporated into the design. Theregions that will adhere to bone, when desirable, may be formed of cpTito enhance bone attachment, and/or incorporate specific 3D textures,modulus, other materials (such as oxides, minerals, glasses) orincorporate other properties to promote bone attachment and ingrowththat are known in the art.

In some embodiments, the material and device-bone material interface isdifferent in different locations, such as to provide differentinterfaces with cortical and cancellous bone to alter attachment andlocal biomechanical interaction. FEA mechanical simulations of tissuesand the implant are used to optimize the interaction to provide bestpossible function and minimize stress shielding. In addition tovariations of the prosthetic material and the material thickness,internal material structures such as honeycombs, struts or ribs may bedesigned in to tailor the local and the global biomechanics of thedevice.

In some embodiments, as required for an application, the implant isdesigned in multiple components. For example, it is clinically desirableto bridge or surround ligament attachments that are otherwise healthyfor reconstruction of a diseased or traumatized pelvis. Separate,attachable, components of the implant are then designed to surround suchstructures, and the components are then assembled and attached asnecessary in surgery. FIG. 5 represents an implant 20 having opposinganchor ends 22 that are adjustably connected using a sliding bridge 24.In use, such an implant may be used to reconstruct the traumatizedpelvis FIG. 6. In some embodiments, the two anchor ends are producedaccording to the data obtained using MRI and CT images as discussedabove and shown in FIG. 3A-D. The anchor ends 22 are put in place,spanning the damaged area and the bridge 24 holds the anchors ends 22together. Further, it should be appreciated that using the methodsdescribed herein, the anchor ends (or any other part of the device) maybe constructed with variable thickness and shape to best fit the pelvictissue and provide the appropriate biomechanical properties.

In some embodiments, as required for a specific application, theprosthetic may be designed with intrinsic adjustability to alter the fitduring surgery using features such as sliding joints (e.g. slidingdovetails) or overlapping plates (FIGS. 5 and 6), item 24. Such featuresmay also be used to alter fit post-surgery if required due to growth orother factors or needs. Such an adjustable fixture includes an internalIlizarov device to enable the expansion or lengthening of long bones.Access to the adjusting structure is designed so that such alterationsare made with minimal surgical trauma, such as minimally invasively.

In some embodiments, the final design of the implant is createddigitally using CAD solid modeling to precisely match the factorsdetermined above. This includes the overall shape, choice of material ormaterials, thickness and thickness gradients at all locations, design ofinternal structures such as honeycombs to provide ideal modulus,placement of pre-engineered standard elements, surface materials (ifdifferent from bulk), surface texture, and any other necessary features.The spatial resolution of the design is ˜10 μm to correspond with themanufacturing resolution and material handling capabilities of thedirect manufacturing tooling and processes. In some embodiments, volumeis added automatically for production so that a higher tolerance surfacecan be created from grinding away the extra volume into the originallydesigned shape.

In some embodiments, the general fit of the device is designed based onthe shape of the tissue it will interact with, as primarily determinedfrom the CT, MRI, PET, digital X-ray, ultrasound and related calibratedmedical imaging data. In addition, for some tissues such as maxillary,facial and skull reconstruction where external appearance is critical,quantitative external imaging and shape scanning are used to obtain goodesthetics using 3D laser surface scanners (FIG. 4).

Loopback:

In some embodiments, the desired shape of the implant is evaluated withrespect to the intended surgical procedure based upon multiple factors.These include biomechanical FEA of tissue and FEA of implant material,joint articulation simulation, mechanisms for short-term and long-termtissue bonding and attachment, desired surgical procedure, materialchoices, and the incorporation of any pre-engineered standard elementsin the implant.

In some embodiments, FEA mechanical simulations of tissues and theimplant are used to optimize the interaction to provide best possiblefunction and minimize stress shielding.

Articulating Joint Simulation, 3.6: In some embodiments, the implant andsurgical procedure at or near an articulating joint in the body of asubject (e.g. hip or knee). In some embodiments, it is necessary tosimulate the function of a joint at or near the implant site.Computational analysis provides an assessment of joint range of motion,joint strength, joint durability, etc.

Finite Element Analysis, 3.7: In some embodiments, Finite elementanalysis (FEA) is performed. FEA is a computer simulation technique inwhich the object is represented by a geometrically similar modelconsisting of multiple, linked, simplified representations of discreteregions or finite elements on an unstructured grid. See, for example,Finite Element Methods for Structures With Large Stochastic Variations,Elishakoff, 1. and Ren, Y, 2003; Finite Element Methods With B-Splines,Hollig, K., 2003. Standard elements may include articulation components(such as the ball and socket of a prosthetic hip joint), joinery toenable multiple sections of an implant to be assembled and attachedduring the surgical procedure, and design features to enable the deviceto be adjusted in size or shape during the initial implantation and at afuture time post-implantation, if desired. FEA provides a mathematicalmethod to solve the limitations of the implant based on the geometricdesign and material type used.

Table 2 outlines the methodology for FEA simulation.

1 Identify possible bone conditions from medical imaging 2 Import solidmodel(s) (e.g., .igs or .stp file format) 3 Assign material properties 4Define connectivity between solid models 5 Define fixed regions, otherknown displacements and boundary conditions 6 Define known loads basedon activity level 7 Select mesh element type and size 8 Mesh convergencestudy 9 Define linear or non-linear solution type 10 Define requiredoutput variables 11 Solve 12 Assess results 13 Identify functionalchanges or capabilities based on results

In some embodiments, pre- and post-operative clinical and biomechanicalassessments will be made for functional assessment of the personalizedimplants. Clinical evaluations include joint range of motion andstrength testing. For biomechanical assessment FEA simulations will beused to develop geometric CAD solid models with the implant in-situthrough virtual surgical operation simulating the actual surgery done tothe subject. A number of 3D elements (e.g. tetrahedral, hexahedral,wedge or some combination thereof) are used to create finite elementmeshes of the geometric models. Mesh convergence analysis is conductedfor accurate simulations. Various loading conditions as obtained fromthe literature and pre- and post-operative functional testing of thesubject are tested to predict stress localization in the interface andstress shielding. Model parameters are obtained from the image data andmaterial testing of biopsy specimens harvested during surgery. A linearstatic analysis is conducted to obtain solutions. As needed, moresophisticated analysis such as nonlinear and transient analyses isconducted to reflect the level of physical activities of the subject.The simulation results are cross-validated with those from the pre- andpost-operative functional testing and further biomechanical assessmentsare done accordingly.

In some embodiments, based on the results of the FEA and jointarticulation, the Device fixation and/or Device design may need to beupdated. Once the design is validated through the previous simulations,the CAS programming can be generated (and/or updated) and the designrationale will be presented to the surgeon in a collaborative designsession that can be performed remotely.

CAS Offline Programming, 3.8: In some embodiments, the computer assistedsurgical (CAS) system is programmed offline. The CAS program referencesthe resection geometry. The CAS robotic resectioning process is verifiedusing a virtual 3D model of patient anatomy. Robotic surgery issimulated for the resection profile. Optimum location for bone removal,edge smoothing, and hole cuts are all matched to the device design.

Example IX Pre-Surgical Collaboration Second Embodiment

In some embodiments, using the methods and technology described hereinand based on FIG. 13, the designed components are collaborativelyreviewed and authorized for production. The surgeon reviews thepreliminary design and makes modifications if desired. If modificationsare made, simulations (FEA, articulating joint and CAS) are repeated tovalidate the implant. Once the surgeon authorizes the component designs,then an order for all required components can be created.

Review Device Design and Simulation Results, 4.1: In some embodiments,the surgeon makes clinical evaluations in the collaborative designsession to determine the desired morphology of areas to be resectionedand an initial determination is made of how an implant will be shaped tomake the necessary repair. Additional clinical data may also be used inthis determination, as appropriate based on the best possible medicalpractice. The surgeon, through the haptics graphical user interface isable to offset the RRP by a constant or variable offset of the RRPvariably based on his/her discretion.

In some embodiments, additional clinical information includes subjecthistory for relevant parameters including a complete medical historywith emphasis on factors that alter strength of tissues such as generalhealth, anthropometric measures such as height and weight, activity,skeletal and connective tissue health factor including bone density, andothers that are critical for application. (FIG. 3A-3D).

In some embodiments, the transfer of information to and from surgeon isperformed with a virtual 3D digital model of subject data that iscalibrated for image spatial/spectral resolution and processed toaccurately replicate the physical dimensions of the subject-specificanatomical structures.

Make Design Changes, 4.2: In some embodiments, this step includes allthe capabilities of Steps 3.4 and 3.5. This dataset is transmittedelectronically to the clinician who is able to manipulate the digitalmodel dynamically in order to view any necessary aspect of thestructure. Using virtual collaboration software, the surgeon then marksthe area for any necessary clinical manipulation such as excision, andlabels additional areas such as desirable locations for attachment ofthe prosthetic, regions that must be left alone, and provides otherannotations regarding the surgical procedure and factors that should beaddressed in the design of the final implant. This data is thencommunicated, digitally in some embodiments, back to the manufacturingfirm where further evaluation and design is performed.

Perform Virtual Surgical Simulation, 4.3: In some embodiments, theimplant design is evaluated by the clinician using virtual 3Dpresentation methods and/or solid models as illustrated in FIGS. 3A-3Dand 4A-4D. Fit is checked, methods of attachment to healthy tissues areevaluated, methods of assembly of implant components (if multiplecomponents) are evaluated, and the entire surgical procedure isperformed “virtually” using 3D display and related methods and/or withsolid models. If required, steps 3 and 4 shown in TABLE 2 andsimulations are repeated until a final digital design and surgical planare made and the surgeon and engineers approve the design.

Authorize the Designs, 4.4: In some embodiments, both the device and theprocedures are authorized. After authorization, an order is created thatleads to the production of all Device components and an optionalphysical model for patient education.

Example X Produce Device Components Second Embodiment

In some embodiments, using the methods and technology described hereinand based on FIGS. 14A and 14B, a patient-specific solution is produced.

In some embodiments, the firm manufactures a personalized implant in 48hours or less. Additive manufacturing technology is used to produce anear-net-shape implant, a tool path program is created using theauthorized implant shape, the five-axis finishing operation program isproved out virtually using simulation, multi-axis grinding and polishingmachines manufacture the implant, and nearly all hand or manual labor iseliminated as well as associated costs. Dimensions are then verified andfinish quality is confirmed, the implant is cleaned and biomaterials areadded, and the implant is sterilized, packaged and shipped to surgeon.

In some embodiments, the term Device has referred to the primary deviceto be implanted (e.g., hip, knee) but typically includes the collectionof all Device Components. A Component could be the Device (e.g., traumaplate), or a part of a Device (e.g., ball and socket), or a surgicaltool (e.g., Cutting Tool) or other part (e.g., Screw) used to implantthe Device.

Produce Component, 6.1: In some embodiments, each component of theDevice designed and authorized is produced using additive manufacturingtechnology. Production of each component is performed with the desiredmaterial or materials directly from powdered metals (and certain othermaterials) that are delivered to the desired spatial location and thenlaser annealed in place (using, for example, DMD, LENS or the like) orannealed using an electron beam (EBM). This produces a very highstrength fine-grain structure, enables the production of internalfeatures, enables layers of multiple materials, gradients of materialproperties, inclusion of ancillary internal elements, and producesresultant structures that generally require minimal post-productionprocessing.

In some embodiments, multiple materials are applied sequentially,regionally, and in designated locations, if required to achieve desiredproperties For example, the bone interface aspect of a bulk Ti6Al4V ELIimplant can be produced with cpTi to enhance bone bonding, or a gradientof materials may be created to affect galvanic processes.

In some embodiments, Nitinol shape-memory alloy structures can beentirely Ti on the surface to minimize Ni toxicity.

In some embodiments, and as desired during the additive manufacturingapproach, the process may be stopped and an element may be added,followed by continued additive processing. Such elements can includefunctional sensors such as MEMS devices including, but not limited to,neuronal, neuromuscular or skeletal stimulators, optical elements suchas lens, structural elements such as ceramic whiskers, or other elementsto provide functional or other capabilities. Any material or device canbe incorporated that is not damaged by the thermal, optical and otherconstraints posed by the laser or electron additive manufacturingprocess, and in consideration of the laser or electron additivemanufacturing process resolution limits.

In some embodiments, volume is added automatically for production sothat a higher tolerance surface can be created from grinding away theextra volume into the originally designed shape, per step 6.3.

Structural Treatments, 6.2: In some embodiments, Additional processingsuch as ion beam implantation or annealing may also be performed. Thesurface texture resolution of the additive manufacturing process iscurrently ˜10 μm with no rough or abrupt transitions. It is thusintrinsically suitable for many tissue interfaces without furtherprocessing. For example, this texture limit can enable the directproduction of tissue interfaces with features that may be as small as 10μm, or larger features as desired in order to enhance tissueinteractions such as bone growth into the implant. Other post-productionprocesses include ion beam implantation, as is routinely used to hardenbearing surfaces in prosthetic knees and hips, as well as annealing andother thermal treatments to effect material structure.

Grind and Polish Component, 6.3: In some embodiments, post-productionprocesses include subtractive manufacturing processes for finishmachining operations, grinding and polishing as may be required forjoining surfaces and for bearing surfaces, such as in articulationjoints, etc. The grinding/polishing makes the precision of the surfacehigher than just from Additive Manufacturing, but this step may not berequired when the component does not have an articulating joint surface.

Label with Unique ID, 6.4: In some embodiments, a component is etched orotherwise labeled or tagged with a unique ID for further trackingthrough the process and during long-term monitoring and/or post-revisionevaluation.

Qualify Component, 6.5: In some embodiments, each Device Component ischecked to ensure that the Shape and Structure from Production, as wellas all post-production operations meet the required levels of quality.Any component that fails this quality check will be sent back throughthe previous process steps for correction or re-production.

Clean Component, 6.6: In some embodiments, quality of a medical implantdevice depends on the proper cleaning of the device during processing.Residue-free implants are help to reduce rejection due to insufficientsurface quality. Contaminants can cause patients pain and inflammationand may lead to implant failure. In some embodiments, the presentinvention provides any cleaning procedure suitable for yieldingcontaminant-free and residue-free device components including forexample one or more of sterilization, ultrasonic cleaning, chemicaltreatments (e.g., decontaminating agent, detergent, etc.), high pressuretreatment, high temperature treatment, abrasion, ion beam cleaning,combinations thereof, etc.

Add Biomaterials, 6.7: In some embodiments, biomaterials will be addedto the orthopedic device. These biomaterials will stimulate bone growthand/or provide drug eluting functionality. In some embodiments, thesebiomaterials will be stem cells and in others they will be antibiotics.

Sterilize Components, 6.8: In some embodiments, the components aresterilized. In some embodiments, any suitable method may be used tosterilize the components. In some embodiments, gamma ray irradiation isused to sterilize the components. In some embodiments, this step mayhappen before or after packaging. In some embodiments a gamma rayirradiation facility is used for mass sterilization of medical devicecomponents.

Assemble Sub-Components, 6.9: In some embodiments, multiple componentswill need to be combined (assembled) to make up a single multi-partcomponent.

Package Component, 6.10: In some embodiments, the components arepackaged to protect the component from the harshness of the shippingprocess, to maintain cleanliness, and to assure a sterilized componentis received by the customer. In some embodiments, each component ispackaged separately. In some embodiments, sub-assemblies (multiplecomponents) are packaged as an assembled medical device.

Check Quality of finished Component, 6.11: In some embodiments, thequality of the components will be checked. In some embodiments, this isa geometrical feature check used to assure dimensional or surfaceintegrity. In some embodiments this is a check of the quantity ofbiomaterials application and processing.

Get all non-personalized Components, 6.12: In some embodiments,components are required that do not have to be ‘produced’ specificallyfor this order and are likely either acquired or pulled from inventory.The production or ordering of these non-personalized components is partof a separate process.

Assemble all Order Components, 6.13: In some embodiments, all componentsof the order need to be collected together to complete the Order andprepare for shipping. This activity includes both company-producedpersonalized components as well as all non-personalized components frominventory.

Ship the Order, 6.14: In some embodiments, all device components need tobe shipped to the appropriate location, ensuring that they arrive withinthe agreed timeframe. Shipping details are provided to the appropriatesurgeon and facility.

Example XI Long-Term Monitoring Second Embodiment

In some embodiments, using the methods and technology described herein,the patient-specific solution is monitored throughout the device'sactive use and, where applicable, upon revision of the device.

In some embodiments, after some time for healing, periodic evaluationsare made by a variety of clinicians. This may include orthopedicsurgeons, radiologists, physical therapists or some combination of theseprofessionals. These professionals periodically send updates to theengineers. The engineers include the results in the patient registry todocument success rates. A registry tracks the patient progress over thelife of the patient. It will also be used for reference in future devicedesigns. In some embodiments, the registry comprises a database that isreferenced by the case-based expert systems utilized in preliminarydevice design. The patient profile information is also used for furtherjoint articulation simulations to validate the simulation methodology.

What is claimed is:
 1. A method of personalizing a biocompatible device,comprising the steps of: (a) obtaining a profile of the subject, whereinsaid profile comprises imaging of said subject; transferring the subjectprofile to a design/manufacturing team and generating a subject profileand case number; (b) producing a virtual 3D design model, wherein saidvirtual 3D design model is configured to the parameters from saidimaging of said subject; and (c) producing a biocompatible device,wherein said biocompatible device is configured to the subject profileand 3D design model.
 2. The method of personalizing a biocompatibledevice of claim 1, wherein said imaging comprises CT (computedtomography), MRI (magnetic resonance imaging), PET (positron emissiontomography), digital X-ray, and ultrasound.
 3. The method ofpersonalizing a biocompatible device of claim 1, wherein producing avirtual 3D design model comprises calibrating, analyzing and producing a3D CAD (computer-aided design) solid model from said imaging data. 4.The method of personalizing a biocompatible device of claim 1, whereinproducing a virtual 3D design model comprises methods selected from CAD(computer-aided design), CAM (computer aided manufacturing), FEA (finiteelement analysis) of biological tissue of the subject, FEA of materials,joint articulation simulation, solid modeling or 3D visualizationinstruments and methods.
 5. The method of personalizing a biocompatibledevice of claim 1, wherein producing a virtual 3D design model comprisesthe steps of: i) creating a 3D surface model of the bone of the subject,wherein said 3D surface model is configured to the parameters from saidimaging of said subject; ii) creating a preliminary exact fit model of avirtual model or a physical model, wherein said preliminary exact fitmodel is configured to the parameters from said imaging of said subject;and iii) designing a personalized biocompatible device, wherein saidpersonalized biocompatible device is configured to accurately fit withsaid 3D surface model of the bone of the subject, subject profilevariables, and quality of the preserved bone.
 6. The method ofpersonalizing a biocompatible device of claim 1, further comprising astep following step (b) but prior to step (c) of evaluating said virtual3D design model.
 7. The method of personalizing a biocompatible deviceof claim 6, wherein evaluating said virtual 3D design model comprises:a) performing a device simulation to analyze said virtual 3D designmodel; b) performing FEA (finite element analysis), wherein said FEAassesses function of said personalized biocompatible device based on asubject profile; c) using a hybrid model to validate said virtual 3Ddesign model; and/or d) performing surgical simulation.
 8. The method ofpersonalizing a biocompatible device of claim 1, further comprising thestep following step (b) but prior to step (c) of programming a CAS(computer assisted surgery) system and verifying the CAS program using avirtual 3D model of said subject.
 9. The method of personalizing abiocompatible device of claim 1, further comprising the step followingstep (b) but prior to step (c) of collaborating between the surgicalteam and the design/manufacturing team to review and optionally modifysaid virtual 3D design and to finalize the design of said personalizedbiocompatible device.
 10. The method of personalizing a biocompatibledevice of claim 9, wherein modifications are evaluated by finite elementanalysis, surgical simulation, device simulation, hybrid model, and/orCAS (computer assisted surgery).
 11. The method of personalizing abiocompatible device of claim 1, wherein said manufacturing saidbiocompatible device comprises manufacturing a 3D physical model of saidbiocompatible device and a 3D physical model of the bone of saidsubject.
 12. The method of personalizing a biocompatible device of claim1, wherein said manufacturing the biocompatible device comprisesadditive manufacturing technology, multi-axis grinding and polishing,and/or verifying finished quality and dimensions of said biocompatibledevice.
 13. The method of personalizing a biocompatible device of claim1, wherein said manufacturing the biocompatible device comprisessterilization of said biocompatible device.
 14. The method ofpersonalizing a biocompatible device of claim 1, further comprising thestep following step (c) of implanting said personalized biocompatibledevice into said subject.
 15. The method of personalizing abiocompatible device of claim 1, further comprising the step followingstep (c) of verifying the fit of said biocompatible device, wherein saidverifying comprises CT (computed tomography), MRI (magnetic resonanceimaging), PET (positron emission tomography), digital X-ray, ultrasound,and other scanning of said subject and said biocompatible device. 16.The method of personalizing a biocompatible device of claim 1, furthercomprising the step following step (c) comparing actual implantationresults to device simulation.
 17. The method of personalizing abiocompatible device of claim 1, wherein said device is selected from agroup consisting of a skeletal orthopedic prosthesis or implant, adental prosthesis or implant or a soft tissue or hard tissue prosthesisor implant.
 18. The method of personalizing a biocompatible device ofclaim 1, wherein said biocompatible device is manufactured frommaterials selected from a group consisting of CoCrMo alloy, Titaniumalloy, Ti6, cpTi, medical grade stainless steel, Tantalum, Tantalumalloy, Nitinol, ceramics, oxides, minerals, glasses and combinationsthereof.
 19. The method of personalizing a biocompatible device of claim1, wherein said biocompatible device has internal structure or surfaceselected from a group comprising honeycombs, struts, ribs, hollow, solidor combinations thereof.